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RELATED PATENT INFORMATION
[0001] This application claims the benefit and priority from U.S. provisional patent application, Ser. No. 60/338,271, filed on Nov. 8, 2001, which is incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates, in general, to an improved tissue pad and blade for use in an ultrasonic surgical instrument, such as an ultrasonic clamp coagulator.
BACKGROUND OF THE INVENTION
[0003] Ultrasonic surgical instruments are finding increasingly widespread applications in surgical procedures by virtue of the unique performance characteristics of such instruments. Depending upon specific instrument configurations and operational parameters, ultrasonic surgical instruments can provide substantially simultaneous cutting of tissue and hemostasis by coagulation, desirably minimizing patient trauma. The cutting action is typically effected by an end-effector at the distal end of the instrument, with the end-effector transmitting ultrasonic energy to tissue brought into contact therewith. Ultrasonic instruments of this nature can be configured for open surgical use, laparoscopic or endoscopic surgical procedures.
[0004] Ultrasonic surgical instruments have been developed that include a clamp mechanism to press tissue against the end-effector of the instrument in order to couple ultrasonic energy to the tissue of the patient. Such an instrument is disclosed in U.S. Pat. No. 5,322,055, hereby incorporated in its entirety by reference.
[0005] Various configurations have been known for the ultrasonic end-effector of the above type of clamp coagulator apparatus. The various configurations optimize the manner in which tissue is coupled to the end-effector or blade, with particular attention paid to achieving the desired degree of tissue cutting and concomitant coagulation.
[0006] With current instrumentation surgeons may improve the speed of cutting with these devices by increasing the clamping force of the instrument but this lowers the amount of coagulation that is done to the tissue and thus lowers hemostasis. This effect is more dramatic at higher blade amplitudes for a given blade geometry. Achieving first-cut hemostasis with currently available ultrasonic instruments usually requires the surgeon to apply energy in one of a number of ways. In one instance, the surgeon may utilize different aspects of the blade (blunt and sharp surfaces). They first apply energy to the structure with the instrument in “blunt” mode, to coagulate the structure, and then to transect it with the “sharp” mode of the instrument. This is time consuming, therefore more advanced surgeons have adopted a second methodology that makes an improved cut by varying the pressure applied to the structure during the course of the energy application. Experience with current instrumentation has shown that lower application of pressure will coagulate the tissue structure while a higher application of pressure will transect the tissue structure. Though this method is faster and does give a first-cut hemostasis, it may at times be difficult to perform correctly and difficult to reproduce.
[0007] It has also been observed that ultrasonic devices may make an uneven cut when grabbing large bites of tissue. This occurs because the tip velocity of ultrasonic devices drops off sinusoidally as a function of the distance from the node to the tip. When a constant force is applied to tissue (homogeneous and isotropic) with a blade that has an energy profile that is sinusoidal, the energy delivered to the tissue has the same sinusoidal profile. This varying energy profile directly affects both the coagulation and cutting tissue effects and causes both of these tissue effects to vary depending upon the location of the tissue within the jaw.
[0008] In conventional ultrasonic medical devices, as for example, disclosed in U.S. Pat. No. 5,322,055, the tissue is pressed against the side of an active blade by a clamp arm or clamping device. In this configuration the tissue presents a frictional drag load to the resonant system. The frictional drag to the system is overcome as the generator applies more energy to the blade and tissue proportional to the frictional drag on the system. The tissue frictional drag is a function of at least two parameters, blade velocity and the applied force at the tissue/blade interface. In most systems the blade velocity is user selected at the generator and remains a constant throughout a single cut. The blade velocity, however, does vary along the length of the blade. In typical systems the blade velocity is greatest at the distal end of the blade and drops off roughly sinusoidal moving proximally to the first waveguide node. The force at the tissue/blade interface is created by the compression of the tissue to the blade, by the clamp arm, which is a function of the pressure applied by the surgeon at the instrument interface. Therefore, if an instrument could vary the compression exerted upon the tissue across the cross section in a single cut, it could control the amount of inflowing energy and therefore, the tissue bio-effect.
[0009] Compression is important because tissue is visco-elastic. Therefore when it is compressed between two structures, such as the ultrasound blade and the clamp arm, it will demonstrate both viscous and elastic properties. Due to the viscous nature of the tissue it will flow out of the instrument jaws slightly. The elastic nature allows the tissue, when compressed, to act like a spring. This means that the force exerted by the tissue on both interfacing surfaces, clamp arm and instrument blade, is proportional to the distance that the tissue has been compressed. Therefore, as the compression distance of the tissue varies the energy delivered to the tissue varies and thus the achieved bio-effect varies. As the surgeon decreases the force of their grip the tissue is compressed a smaller distance and the energy delivered to the tissue is reduced, resulting in a reduced energy transfer during coagulation of the tissue. As the force and thus tissue compression are increased, the energy delivered to the tissue increases, and a cut is achieved. However, the cut will likely appear in the same vicinity as the coagulation, which may reduce the sealing effect.
[0010] It would be desirable to provide a ultrasonic clamp coagulator to optimize the tissue effects discussed herein. The present invention is particularly directed to an improved clamp arm arrangement, including a tissue pad having a varying height surface. The tissue pad and blade of the present invention have been developed to address this desire.
SUMMARY OF THE INVENTION
[0011] Disclosed is an ultrasonic surgical instrument that combines end effector geometry to best affect the multiple functions of an ultrasonic clamp coagulator. These end-effectors contain a combination of specially shaped ultrasonic blades and tissue clamping pads that can be used in combination or separately and that control the amount of cutting and coagulation that occurs during use. These combinations accomplish this by controlling the amount of compression that the tissue sees as it is pressed against the active blade, leading to a custom coagulation and cut zone.
[0012] In particular the invention presents a compression zone designed to control the amount of energy delivered to a specific part of the tissue by varying the compression on the tissue with a single application of clamping force. Since the compression force is directly proportional to the distance of compression the invention features a clamp arm with a tissue interface pad having a varied height to control the tissue effect. By placing the cut zone directly between two coagulation zones, a zone of coagulation is created on each side of the cut, increasing the reliability of the seal. In an alternate embodiment the blade may comprise a tissue interface surface having a varied height to control the tissue effect.
[0013] In one embodiment the invention controls both the cutting zone and the coagulation zone in the form of a tissue pad having compression cross-section similar to a step. The highest portion of the pad causes more energy to be directed to the tissue and causes cutting, while the lower portion of the pad causes less compression and causes the tissue coagulation. Alternatively, the tissue pad may have a varying cross-sectional height dimension instead of a step.
[0014] In an alternate embodiment, the dimensions of the tissue pad change from the distal end of the blade to the proximal end of the blade. In one embodiment the raised section of the tissue pad has a varying height from the distal end of the blade to the proximal end of the blade. Alternatively, the coagulation zone section of the pad has a varying height from the distal end to the proximal end of the blade. In another embodiment the width of the raised section of the tissue pad varies from the distal end to the proximal end of the tissue pad (or blade).
[0015] In still a further embodiment, a tissue pad with a continuously rounded tissue-contacting surface is opposed to a blade with a similar continuously rounded tissue-contacting surface such that when brought into contact, the center sections of the tissue pad and blade contact to create a cut zone, while the remainder of the two parts create two coagulation zones on either side of the cut zone. These coagulation zones, by the curved nature of the tissue pad and blade generate zones with compression that decrease as a function of the distance from the cut zone. This enables an improvement over the stepped tissue pad design in that this embodiment is accommodating to a wider range of tissue thickness.
[0016] A further embodiment of the invention employs a trough, or U-shaped clamping surface. This embodiment provides a much wider coagulation zone than conventional clamp/coagulator pad designs. The U-shaped clamping surface also insures that the tissue sample is “wrapped” to the ultrasonic blade in order to put the tissue in contact with the blade in compression mode, regardless of the instrument's orientation. Having the tissue cut surface in compression keeps the tissue in the jaw and allows for an improved sealing of tubular structures such as blood vessels.
[0017] As would be apparent to those skilled in the art, the present invention has, without limitation, application in conventional endoscopic and open surgical instrumentation as well as application in robotic-assisted surgery.
[0018] These and other features and advantages of the present invention will become apparent from the following more detailed description, when taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The novel features of the invention are set forth with particularity in the appended claims. The invention itself, however, both as to organization and methods of operation, together with further objects and advantages thereof, may best be understood by reference to the following description, taken in conjunction with the accompanying drawings in which:
[0020] FIG. 1 a is a perspective view of an ultrasonic end-effector having a clamp tissue pad with a raised surface;
[0021] FIG. 1 b is a perspective view of an ultrasonic end-effector and an alternate embodiment of a clamp tissue pad with a raised surface;
[0022] FIGS. 2-5 are cross-sectional views of the blade and alternate embodiments of the tissue pad;
[0023] FIG. 6 is a perspective view of an ultrasonic end-effector and an alternate embodiment of the tissue pad;
[0024] FIG. 7 is a cross-sectional view of the tissue pad and blade of FIG. 6 ;
[0025] FIGS. 8 and 9 are schematic representations of tissue compressed between a clamp pad and sharp-edged blade and resulting tissue effects;
[0026] FIGS. 10 and 11 are schematic representations of tissue compressed between a clamp pad and round-edged blade and resulting tissue effects;
[0027] FIGS. 12 a - b are alternate embodiments of a clamp pad having a raised surface;
[0028] FIG. 13 is a perspective view of an ultrasonic end-effector and an alternate embodiment of the tissue pad;
[0029] FIG. 14 is a cross-sectional view of the tissue pad and blade of FIG. 13 ;
[0030] FIG. 15 is a schematic representation of the velocity change along the length of the blade;
[0031] FIG. 16 is an elevation view of the tissue pad and blade of FIG. 13 ;
[0032] FIG. 17 is a cross-section view of an alternate embodiment of the blade in cooperation with a “U”-shaped clamp pad;
[0033] FIG. 18 is a cross-section view of an alternate embodiment of a “U”-shaped clamp pad in cooperation with the blade of FIG. 17 ;
[0034] FIGS. 19-20 are schematic representations of the tissue effects dependent upon the position of the blade; and
[0035] FIGS. 21-22 are schematic representations of the tissue effects in conjunction with the embodiment of FIG. 17 .
DETAILED DESCRIPTION OF THE INVENTION
[0036] Before explaining the present invention in detail, it should be noted that the invention is not limited in its application or use to the details of construction and arrangement of parts illustrated in the accompanying drawings and description. The illustrative embodiments of the invention may be implemented or incorporated in other embodiments, variations and modifications, and may be practiced or carried out in various ways. Furthermore, unless otherwise indicated, the terms and expressions employed herein have been chosen for the purpose of describing the illustrative embodiments of the present invention for the convenience of the reader and are not for the purpose of limiting the invention.
[0037] It is also understood that any one or more of the following-described embodiments, expressions of embodiments, examples, methods, etc. can be combined with any one or more of the other following-described embodiments, expressions of embodiments, examples, methods, etc. For example, and without limitation, any of the energy directors can be used individually or in combination with the end-effectors described herein.
[0038] In addition, the dimensions given for the energy directors and other structures are exemplary in nature only, and are not intended to limit the scope of the invention.
[0039] Further, the present invention will be illustrated in the form of a straight blade and useful in the devices as exemplified in U.S. Pat. Nos. 5,322,055; 5,873,873; 5,954,746; 6,214,023 and 6,254,623, all of which are incorporated by reference herein in their entirety. The invention has equal application in ultrasonic devices having curved blades as exemplified in U.S. Pat. Nos. 6,283,981; 6,325,811 and 6,432,118, all of which are incorporated by reference herein in their entirety.
[0040] FIG. 1 shows an end-effector 20 of an ultrasonic clamp/coagulation medical instrument. Shown in the figure is the distal end of the instrument 10 including; the instrument shaft 12 , the ultrasonic blade 22 , which extends out of the instrument shaft 12 , the movable clamp arm 24 , which pivots with the instrument shaft in the direction shown. The clamp arm 24 includes a tissue pad 26 , preferably formed from Teflon or other suitable low-friction materials, which is mounted for cooperation with the blade 22 . With this construction, tissue is grasped between the tissue pad 26 and the blade 22 . FIG. 2 shows a cross section of the tissue pad 26 and the ultrasonic blade 22 . This cross section illustrates the three important dimensions of the above device; Wb, Wp, and Wd. Wb is the overall width of the blade itself, and Wp is the width of the raised portion or energy director 28 of the tissue pad 26 . Ideally the ratio of Wp to Wb would be some value less than one that would determine the ratio of cutting to coagulation that would occur when the instrument is in use. The preferred range of the ratio of Wp to Wb would be less than about 1:2; however, the dimension of Wp may be as low as 0.001 inches. Wd is also very important because it determines the ratio of energy application between the tissue under the raised clamp portion 28 and the tissue under the remainder of the blade width. The higher the value of Wd, the less coagulation will occur in the zone of tissue on either side of the raised portion 28 . The ratio of Wd to Wp is preferred in the range of greater than 1:4 and less than 2:1. However, more importantly is the ratio of Wd to the anticipated tissue thickness. Wd needs to be less than the overall thickness of the tissue being transected, thus applying pressure in the coagulation zone as well as the cut zone.
[0041] As is well known to those skilled in the art, the clamp pad 26 and raised portion 28 may be modified to include in combination or individually gripping teeth 25 to enhance the tissue-gripping capabilities of the end-effector as shown in FIG. 1 b . Teeth 25 may be arranged as disclosed in U.S. Pat. No. 6,068,647.
[0042] FIGS. 3 through 5 show alternate embodiments of the tissue pad 26 and blade 22 for use with the ultrasonic clamp/coagulation instrument 10 of FIG. 1 with like reference numerals having the same description as given in FIG. 1 . FIG. 3 illustrates the tissue pad 26 having a raised clamp portion, or energy director, 30 having a triangular cross section. The parameters Wb, Wp and Wd define the same dimensions as in FIG. 2 , but the raised clamp area is further defined by the angle ⊖ 1 . This angle defines a wedge shaped area that would increase cutting speed and would make a thinner cut. The only limitation on the value of angle ⊖ 1 is that the resulting energy director is not so thin as to be structurally unsound.
[0043] FIG. 4 illustrates a tissue pad 26 having two energy directors and a separation distance Wc. Also shown are the critical parameters Wp 1 and Wp 2 , (width of energy directors 32 and 34 , respectively), Wd and Wb. In this embodiment, the energy directors allow the instrument to make multiple cuts of a tissue sample at the same time. This could allow a tissue structure, such as a fallopian tube, to be sealed and ligated and a sample of the tube to be removed. In the case of vessels this embodiment could be used to place a double seal on a vessel. As in previous embodiments, the ratio of Wp 1 +Wp 2 to Wb would determine the ratio of cut tissue verses coagulated tissue and would be similar to the ratios previously discussed. The parameter Wc controls the amount of tissue between the two cuts defined by Wp 1 and Wp 2 . Dimensions of Wp 1 and Wp 2 are similar to previous embodiments, but Wc would be about twice Wp in order to see any effect of spacing, that is, if a sample of tissue needs to be removed.
[0044] FIG. 5 shows a partial cross section of the tissue pad 26 and the ultrasonic blade 22 and an energy director 36 . Dimensions Wb, Wp and Wd define the same dimensions as in FIG. 2 , but the raised clamp area 36 is further defined by the radius r 1 . This radius defines the raised tissue pad section that would give a faster cut than in the embodiment in FIG. 1 but slower than in FIG. 3 . It also would have a wider ratio of cut area to coagulation area. Although FIG. 5 shows the center of r 1 to be aligned such that r 1 is exactly twice Wp, it is also possible for the radius to be offset from this position such that the curve subscribes only a portion of a full diameter. This would allow for radii larger than twice Wp to be used.
[0045] FIGS. 4 and 5 also illustrate alternate energy directors that are incorporated onto the blade 22 . In FIG. 4 , energy directors 32 a and 34 a are shown in phantom on blade 22 in direct opposition to energy directors 32 and 34 . It is possible to use energy directors 32 a and 34 a alone and in cooperation with presently available tissue pads as disclosed in the cited prior art references; alternatively energy directors 32 a and 34 a may be used in combination with energy directors 32 and 34 . Energy director 36 a is shown in FIG. 5 and can be use alone or in combination with energy director 36 . The energy directors located on the blade 22 may be manufactured during the machining process of blade 22 .
[0046] A further embodiment of the invention is shown in FIGS. 6 and 7 with like reference numerals having the same description as FIG. 1 . In this embodiment there is a single energy director 38 , but it is deployed in a non-linear fashion, (ie. curvy path) from the distal end of tissue pad 26 to the proximal end of tissue pad 26 . FIG. 7 illustrates the critical parameters Wb, Wp, Wp 2 , and Wd. Wb is the width of the blade 22 and determines the overall affected area of the tissue. Wd is the height of the energy director 38 and determines the ratio of pressure difference between the cut zone and the coagulated zone. Wp is the width of the energy director and the ratio of Wp to Wb determines the ratio of coagulated tissue to cut tissue. The parameter Wp 2 determines the spread of the path of the energy director across the Wb dimension. Preferably, Wp 2 is about two times Wp and less than Wb. The embodiment illustrated in FIG. 6 has equal application for the previously disclosed embodiments of the invention.
[0047] A further embodiment of the invention is shown in FIGS. 13 through 16 with like reference numerals having the same description as FIG. 1 . In this embodiment, the raised portion, or energy director, 40 has a varying dimension from its distal to proximal end. FIG. 14 illustrates the critical dimensions of the ultrasonic blade and tissue pad, Wb, Wp, Wd 1 and Wd 2 . Wb is the width of the ultrasonic blade and determines the amount of tissue that is affected by the device. Wp is the width of the energy director and the ratio of Wp to Wb determines the ratio of the coagulated tissue to the cut tissue when the device is used. Wd 1 shows the height of the energy director 40 at its distal end while Wd 2 shows the height of the energy director 40 at the proximal end of the tissue pad 26 . Wd 2 is always larger than Wd 1 and the height of the energy director 40 changes linear from Wd 1 to Wd 2 . As is obvious to those skilled in the art, the height of the energy director 40 may also change in a nonlinear fashion.
[0048] FIG. 15 shows a side view of an exemplary end-effector of an ultrasonic clamp/coagulation device with the clamp arm and tissue pad removed for ease of illustration. The graph displays how the velocity of the end-effector varies along the length of the end-effector. Specifically, the end-effector velocity progresses in a sinusoidal fashion, (zero at the node and maximum at the most distal tip of the end-effector). FIG. 16 shows a side view of the clamp arm 24 , tissue pad 26 and energy director 40 shown in FIGS. 13 and 14 and illustrates the dimensions Wd 1 and Wd 2 and shows the transition of the height of the energy director as it progresses from the distal end of the tissue pad to the proximal end of the tissue pad in a non-linear fashion. This transition creates a curved energy director surface that is proportional to the drop off in tip velocity shown in the graph in FIG. 15 , so that as the tip velocity drops off, the height of the energy director increases, thus keeping constant energy delivered to the tissue.
[0049] Preferably, the embodiments of FIGS. 1 through 7 and 14 are used in conjunction with a blade 22 having a rounded cross section. FIG. 8 shows the cross section of the distal end of an ultrasonic clamp/coagulation device as it is compressing a vessel or tubular structure in order to divide the tissue and seal both ends of the divided tissue. As the tissue pad 28 and an ultrasound blade 22 , having discrete edges, are brought closer together by pivoting the clamp arm (not shown), the walls of the tissue, T 1 and T 2 are brought into contact with each other and compressed together. As energy is applied to the tissue through the ultrasound blade 22 and directed by the energy director 28 of FIG. 2 the two walls, T 1 and T 2 , are coagulated and cut. FIG. 9 shows a cross section of the left hand side of the tissue from FIG. 8 after it has been coagulated and divided. A defect in the tissue weld is created due to the visco-elastic properties of the tissue and the sharp corner of the ultrasound blade. This tissue defect causes wall T 2 to be thinned, thus weakening the tissue weld and in the case of vessels, leading to lower burst pressure ratings on the seal. FIG. 10 shows the preferred embodiment of the distal end of an ultrasonic clamp/coagulation device as it is compressing a vessel or tubular structure in order to divide the tissue and weld it. In this embodiment the ultrasound blade has a rounded cross section and does not create sharp corners as in FIG. 8 . In addition as the pressure is applied to the tissue during transection, the high pressure section in the cut zone pushes the coagulum created during the cut to the lower pressure areas in the coagulation zones, which in turn push the coagulum into the uncompressed lumen of the vessel. This coagulum can then cool and form a seal or plug in the lumen that increases the effectiveness of the seal.
[0050] FIG. 11 shows a cross section of the right side of the tissue shown in FIG. 10 after energy has been applied to it and it has been divided and coagulated. Because of the shape of the ultrasound blade there is no tissue defect 1 and therefore no weak spot.
[0051] FIGS. 12 a and 12 b illustrate alternate embodiments of an energy director 28 having a raised area in combination with a curved blade 22 that would provide the tissue effects shown in FIG. 11 . FIG. 12 a shows a trapezoidal-shaped energy director 28 section, which provides for varying compression as a function of the distance from the cut zone. Both embodiments are more robust over a broader range of tissue thickness.
[0052] FIGS. 17 and 18 illustrate a tissue pad 27 and blade 23 useful in conjunction with the ultrasonic cut/coagulation instrument 10 . In this embodiment the tissue pad 27 is U-shaped and having the parameters a and b, and the ultrasonic blade is rectangular in shape and having the critical parameter Wb. The ratio of the parameters a to b determine the ratio of energy delivery to tissue that is directly under the blade as opposed to compressed in the side slots 42 and 44 . The parameter Wb, determines the amount of tissue that is cut as opposed to coagulated. The sides of the tissue pad would help “wrap” the tissue around the ultrasonic blade in order to create larger coagulation zones as opposed to previous embodiments. In FIG. 18 , the U-shaped tissue pad 27 has a complex geometry that includes the angle β. This embodiment would allow the value of parameter b to vary, or increase, as you move vertically along the sidewalls of the tissue pad. This would lower the amount of energy dissipated into these regions, thus causing the amount of coagulation to decrease. The value of angle β would be a matter of design choice depending on the amount of coagulation needed.
[0053] The benefit of the U-shaped tissue pad is best understood by examination of the tissue effects when the tissue is compressed between the tissue pad and ultrasonic blade. Referring to FIG. 19 , a tubular tissue sample is compressed in the between a blade 22 and tissue pad 26 in an “upward” fashion, that is, with the tissue pad 26 on the top. In this configuration, the clamping surface of the tissue is above the cutting surface of the tissue. Due to gravity, the tissue droops down to either side of the ultrasonic blade 22 and asserts a bending force to the tissue structure. This causes the top wall, or the clamping surface, to be in a tensile load and the bottom wall, or cutting surface to be under a compressive load. As the ultrasonic blade works it's way through the tissue the cutting surface would remain in the jaw due to the compressive forces, allowing the two walls to remain in intimate contact throughout the coagulation process and thus creating a better seal.
[0054] FIG. 20 , on the other hand, shows a cross section of the tubular tissue as it is compressed in the jaws with the jaws in a “downward” orientation, that is, the tissue pad on the bottom. In this figure the cutting surface of the tissue is above the clamping surface of the tissue. In this configuration the tissue would have the cutting surface on the top of the bending load, thus applying a tensile force to the tissue as it is cut. Since tissue is visco-elastic, it would snap out of the jaw as it is cut, thus shortening the time that the walls are compressed in the coagulation zone and weakening the seal of the structure.
[0055] FIGS. 21 and 22 both show a cross section of the U-shaped tissue pad and tissue compressed therein. FIG. 21 shows the instrument in the “downward” position with the tissue pad on the bottom and FIG. 22 shows the instrument in the “upward” position with the tissue pad on the top. FIGS. 21 and 22 both show that the cutting surface of the tissue is in the compression side regardless of the orientation of the instrument. The U-shaped tissue pad forces an oriented bending load onto the tissue that is not affected by gravity. Therefore the tissue in contact with the ultrasonic blade is always in the compressive zone, even if the instrument is turned sideways.
[0056] The foregoing description of several expressions of embodiments and methods of the invention has been presented for purposes of illustration. It is not intended to be exhaustive or to limit the invention to the precise forms, dimensions and procedures disclosed, and obviously many modifications and variations are possible in light of the above teaching. For example, as would be apparent to those skilled in the art, the disclosures herein of the ultrasonic systems and methods have equal application in robotic assisted surgery taking into account the obvious modifications of the invention to be compatible with such a robotic system. It is intended that the scope of the invention be defined by the claims appended hereto.
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An ultrasonic surgical clamp coagulator apparatus is configured to effect cutting, coagulation and clamping of tissue by cooperation of a clamping mechanism of the apparatus with an associated ultrasonic end-effector. The clamping mechanism includes a pivotal clamp arm, which cooperates with the end-effector for gripping tissue. The clamp arm is provided with a clamp tissue pad that has at least one raised portion to achieve the desired cutting and coagulation effect on the tissue.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to the automatic limiting of signals. More particularly, the present invention relates to a circuit and method for automatically limiting the amplitudes of broadcast and/or transmitted audio signals.
[0003] 2. Background Art
[0004] The following figures which illustrate the various embodiments of the background art and the present invention may incorporate the same or similar elements. Therefore, where the same or similar elements occur throughout the various figures, they will be designated in the same manner.
[0005] [0005]FIG. 1 illustrates a block diagram of a known circuit for varying the amplitude of audio signals.
[0006] This figure comprises a receiving circuitry 100 and output circuitry 110 and is applicable to an analogue and/or digital system.
[0007] The receiving circuitry 100 and output circuitry could for example be the respective audio front and back ends in a radio, television, video, satellite decoder etc.
[0008] The receiving circuitry 100 receives, via an input 120 , a transmitted or broadcast signal Si. The circuitry 100 then processes the signal Si and outputs, via its output 130 , a first audio, i.e. sound, signal A 1 .
[0009] The input 140 of the output circuitry 110 is connected to the output 130 of the receiving circuitry 100 and thus the output circuitry 110 receives the signal A 1 . The output circuitry 110 then processes the signal A 1 and outputs, via its output 150 , a second audio signal A 2 , which is then fed to a speaker system (not illustrated).
[0010] The output circuitry 110 also receives a control signal C 1 via another input 160 . This control signal C 1 is controlled by the user of the apparatus in which this circuitry of FIG. 1 is utilised. This signal C 1 is used to control the peak, average and/or Root Mean Square (RMS) amplitude of the audio signal A 2 . Therefore, by increasing, for example, the RMS amplitude of the audio signal A 2 , the volume of the signal from the speakers is increased and vice-versa. The user can control the signal C 1 by, for example, a knob or button on said apparatus or by a remote control system that works in conjunction with said apparatus.
[0011] One problem associated with the arrangement of FIG. 1 is that if there is a change in the RMS amplitude of the signal A 1 , then this will be proportionally reflected in the signal A 2 and hence the volume. The effect of this is that the user will have to readjust the control signal C 1 to return the volume emanating from the speakers, i.e. the RMS amplitude of the signal A 2 , to substantially the same level as before the change in the RMS amplitude of the signal A 1 .
[0012] An example of where changes in the RMS amplitude of the signal A 1 occur are in the commercial breaks of television, satellite and radio broadcasts. During these commercial breaks quite often the amplitude of the broadcast audio signal is increased, which results in an increased volume output. The purpose underlying this increase is to stimulate the listener and draw his attention to the commercial and hence the product, service etc. being advertised. However, the increase in the level of the volume can be as much as +6 dB for example, i.e. double the amplitude of the original signal, which results in the listener diving for the control knob/button or scrabbling for the remote control device in order to reduce the volume. Then when the commercial is over, the listener has to readjust the volume back to the acceptable level it was before the commercial.
[0013] Another example of where sudden changes in the amplitude of the signal A 1 occurs is during the tuning of a radio. The strengths, i.e. the amplitudes, of some signals are greater than others and it can be quite disturbing, and in some instances dangerous, when there is a sudden increase in the output volume: this is especially the case if one is tuning a car radio when driving for example.
OBJECTS & SUMMARY OF THE INVENTION
[0014] Accordingly, an object of the present invention is to automatically compensate for variations, whether deliberate or otherwise, in the signals of audio systems and apparatus.
[0015] Another object of the present invention is to automatically maintain the amplitudes of signals within audio systems and apparatus to substantially a fixed level or substantially within a range of one or more levels.
[0016] In order to achieve these objects, the present invention proposes a circuit for processing broadcasted/transmitted signals that comprises: circuitry for receiving and processing the broadcast signals, which contain audio information, and providing a first audio signal; and circuitry for controlling, i.e. adjusting, the amplitude, i.e. the volume, of a received second audio signal in response to a first control signal and providing a third audio signal. The circuit further comprises circuitry, that receives the first audio signal and provides the second audio signal, for automatically limiting or adjusting the amplitude of the first audio signal in response to at least one reference signal.
[0017] According to another embodiment of the present invention, the circuitry for automatically limiting or adjusting the amplitude of the first audio signal comprises: circuitry, that receives the second audio signal, for providing an output signal in response to the amplitude of the second signal; circuitry for comparing the output signal and said at least one reference signal and providing a second control signal in response to the output signal and said at least one reference signal; and circuitry, that receives the first audio signal and that is controlled in response to the second control signal, for providing the second audio signal.
[0018] According to another embodiment of he present invention, the circuitry for providing: the output signal; the second control signal; and for providing the second audio signal are implemented by analogue and/or digital means.
[0019] According to another embodiment of the present invention, the circuitry for providing: the output signal; the second control signal; and for providing the second audio signal are implemented by hardware digital circuitry.
[0020] According to another embodiment of the present invention, the digital means can be represented by one or more digital signal processing algorithms and/or by one or more software routines.
[0021] According to another embodiment of the present invention, the digital means is implemented by any combination of hardware digital circuitry, one or more digital signal processing algorithms, and one or more software routines.
[0022] According to another embodiment of the present invention, the circuitry for providing: the output signal is a Root-Mean Square extractor circuitry; the second control signal is an integrating comparator; and the circuitry for providing the second audio signal is an attenuator.
[0023] According to another embodiment of the present invention, the Root-Mean Square extractor circuitry comprises a series connected rectifier and low pass filter.
[0024] According to another embodiment of the present invention, the circuitry for providing the second control signal comprises a current sourcing/sinking comparator having a capacitor connected between its output terminal and a reference voltage, i.e. ground potential for example.
[0025] According to another embodiment of the present invention, the circuitry for providing the second audio signal is a multiplying digital-to-analogue converter.
[0026] According to another embodiment of the present invention, the circuit is included in an apparatus that receives broadcast and/or transmitted signals.
[0027] According to other embodiments of the present invention, the circuit is included in circuitry and/or an apparatus that receives television, satellite, and/or radio signals.
[0028] The present invention also proposes a method for processing broadcast or transmitted signals that comprises the steps of: receiving and processing the broadcast or transmitted signals, which contain audio information, and providing a first audio signal; and controlling the amplitude of a received second audio signal in response to a first control signal and providing a third audio signal. The method further comprises the step of automatically limiting, i.e. adjusting, the amplitude of the first audio signal in response to at least one reference signal and providing a second audio signal.
[0029] According to another embodiment of the present invention, the step of automatically limiting the amplitude of the first audio signal comprises: providing an output signal in response to the amplitude of the second signal; comparing the output signal and said at least one reference signal and providing a second control signal in response to the output signal and said at least one reference signal; and receiving the first audio signal and controlling said first audio signal in response to the second control signal, for providing the second audio signal.
[0030] According to another embodiment of the present invention, the method is practised in circuitry and/or an apparatus that receives television, satellite and/or radio signals.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] These and other objects, as well as other advantages and features, of the present invention will become apparent in light of the following detailed description and accompanying drawings among which:
[0032] [0032]FIG. 1 has already been depicted as exposing the state of art and the problem to overcome;
[0033] [0033]FIG. 2 illustrates a block diagram of a circuit for automatically limiting the amplitude of audio signals according to the present invention;
[0034] [0034]FIG. 3 illustrates an example of a circuit diagram for automatically limiting the amplitude of an audio signal according to the present invention; and
[0035] [0035]FIGS. 4 a - 4 f illustrate waveforms associated with the circuitry of FIG. 3.
DETAILED DESCRIPTION OF THE INVENTION
[0036] [0036]FIG. 2 illustrates a block diagram of a circuit for automatically limiting the amplitude of audio signals according to the present invention.
[0037] In addition to the circuitry 100 and 110 of FIG. 1, FIG. 2 also includes circuitry 200 for automatically limiting or adjusting the amplitude of the audio signal A 1 in response to at least one reference signal Ref 1 . This reference signal Ref 1 may be pre-defined during the design phase and/or may or may not be adjustable afterwards.
[0038] Since the circuitry 100 and 110 of FIG. 1 has already been described, Its operation will hereafter be omitted for the purposes of brevity.
[0039] According to the present invention, the circuitry 200 comprises: an attenuator 210 , signal processing circuitry 220 , and an integrating comparator 230 .
[0040] A first input 250 of the attenuator 210 , which according to the present invention is preferably variable, is connected to the output 130 of the circuitry 100 and receives the signal A 1 . The output 260 of the attenuator 210 , which carries a second audio signal A 2 ′, is connected to the respective inputs 140 and 270 of the respective circuitry 110 and 220 . The output 275 of the circuitry 220 , which carries a feedback signal FB that is derived from the audio signal A 2 ′, is connected to a first input 280 of the integrating comparator 230 . The second input 285 of the integrating comparator 230 receives the reference signal Ref 1 . The output 290 of the integrating comparator 230 , which carries a second control signal C 2 , is connected to a second input 295 of the attenuator 210 .
[0041] According to the present invention, a purpose of the attenuator 210 , the signal processing circuitry 220 , and integrating comparator 230 is to limit the amplitude of the audio signal A 2 ′, in response to the reference signal Ref 1 , to a desired threshold, by automatically compensating for variations beyond said threshold of the amplitude of the signal A 1 . According to the present invention it is preferable to limit the RMS amplitude, however the present invention can be used to limit the average or peak amplitude of the signal A 1 .
[0042] By way of an example of the operation of the circuit according to the present invention consider the following, which is applicable to television, satellite and radio transmitted broadcasts.
[0043] The attenuator 210 , which could be a network or transducer, is controlled by control signal C 2 , which is in turn controlled by the signals Ref 1 and FB. Assume that, during ‘normal’ broadcast, i.e. when the RMS amplitude of the broadcast audio signal is not deliberately increased, the signals Ref 1 and FB are at values such that the attenuator 210 provides substantially 0 dB's of attenuation: therefore the RMS value of the audio signal A 2 substantially equals that of A 1 . The user controls the output volume from the speakers, i.e. the RMS amplitude of the audio signal A 3 that appears on the output 150 of the circuitry 110 , to its desired level by altering the control signal C 1 , which has the effect of either amplifying or attenuating the signal A 2 ′ within the circuitry 110 . Assume now that the broadcast is not ‘normal’, i.e. the RMS amplitude of the broadcast audio signal has been deliberately increased by +6 dB for example. According to the present invention, an object of the processing circuitry 220 and the integrating comparator 230 is to stimulate the attenuator 210 such that it attenuates the signal A 1 , preferably by the same amount that it was amplified by. Initially, since the attenuator provides an attenuation of 0 dB, the signal A 2 ′ has substantially the same RMS amplitude as A 1 . The increase in the amplitude of signal A 2 ′ is detected by the processing circuitry 220 , whose output signal FB changes as a result of this increase. Assume for example that the FB is a voltage signal that increases from a value V1 to a value V2. Also assume that the reference signal Ref 1 supplied to the integrating comparator 230 is a voltage signal that has a value V3, which is slightly greater than V1, so as to allow for minor increases in the signal FB, but less than V2. As the signal FB increases from V1 to V2 it triggers the comparator 230 so that the control signal C 2 stimulates the attenuator such that its attenuation of the signal A 1 changes rom 0 dB to −6 dB, thereby restoring the level of the signal A 2 ′ to substantially its previous value. It should be noted that the response time for the circuitry 200 to attenuate the amplified signal A 1 will be such that the user will not notice any appreciable change in the output volume of the apparatus.
[0044] In a system where the increase in the signal A 1 during a not ‘normal’ broadcast is fixed: not ‘normal’ in the sense that the broadcast audio signal in purposely increased; it is sufficient enough to fix the amount of attenuation provided by the attenuator 210 so that the attenuator 210 can just be switched on when attenuation is needed and vice-versa.
[0045] However, according to the present invention, it is preferable to be able to have variable attenuation that is controllable so as to be able to attenuate the signal A 1 by the same amount that it was amplified. As an example, assume A 1 is increased by only +3 dB, as opposed to +6 dB, then it is preferable that the attenuator 210 attenuates it by −3 db and so forth.
[0046] It should be noted that, according to the present invention, it is preferable that the user should have the option to be able to control whether or not attenuation during advertising actually takes place or not. The user can therefore control, using control signal C 3 , whether or not the circuitry 200 , or any part of it, operates such that it provides the necessary attenuation, or not as the case may be, during the advertising breaks. The user may control this attenuation function with a switch or button or the like, or alternatively, via a remote control apparatus with, in the case of a television or monitor, an On Screen Display (OSD) facility for example.
[0047] According to the present invention, it is preferable to design a multi-standard system especially for television, video, satellite applications etc. This is easily achieved with the aid of a microcontroller or microprocessor and some memory (not illustrated). The memory can De pre-programmed with various information about the peak, average and/or RMS values of the broadcast signals and even standards throughout the various countries of the world. The correct settings can easily be called up during the assembly and testing phases of the apparatus. The attenuator can then be controlled directly by, or in conjunction with, the microcontroller/microprocessor so that it provides the correct attenuation as and when it is required.
[0048] [0048]FIG. 3 illustrates an example of a circuit diagram for automatically limiting the amplitude of an audio signal according to the present invention.
[0049] The circuitry 200 of FIG. 2 is illustrated in further detail in this present figure. The attenuator 210 comprises a multiplying digital-to-analogue (D/A) converter; the processing circuitry 220 a rectifier 300 and low pass filter 305 ; and the integrating comparator comprises a comparator COMP and an integrator INT.
[0050] The multiplying D/A comprises two voltage followers 310 , 315 and a switched resistive attenuation control circuit 320 . The signal A 1 is applied to the control circuit 320 after having been buffered by the voltage follower 310 . The control circuit 320 receives the control signal C 2 from the comparator 230 . The control circuit 320 can be controlled by a microprocessor or microcontroller (not illustrated), as indicated by the dashed input 325 . This control input 325 can be used to actively adjust the amount of attenuation provided by the control circuitry 320 in response to predetermined references for example. The signal A 2 is derived from the output 330 of the circuit 320 via the voltage follower 315 .
[0051] The rectifier 300 recifies the signal A 2 ′ before it is passed through the low pass filter 305 . The resulting output signal FB from the filter 305 is the Root-Mean Square (<MS) value of the signal A 2 ′.
[0052] The signal FB is compared with the reference signal Ref 1 , so that for example., when FB is greater than Ref 1 , the output signal C 2 from the integrating comparator 230 is a positive ramp, which is used to control the circuit 320 .
[0053] [0053]FIGS. 4 a - 4 f illustrate waveforms associated with the circuitry of FIG. 3.
[0054] It should be noted that the following figures are not to scale and are representations of the underlying principles and that the waveform of FIG. 4 a only illustrates the positive envelope of a broadcast signal.
[0055] When the signal A 1 increases, at time t 0 , from its ‘normal’ value to its increased value, as illustrated in FIG. 4 a , this causes the value of the signal FB to start to increase, as illustrated in FIG. 4 b . When the voltage value of the signal FB becomes greater than approximately that of the reference voltage Ref 1 , the comparator's output 335 , in this particular example, changes to a high state, as illustrated in FIG. 4 c . The resulting output signal C 2 from the integrator, which can be implemented by a capacitor (not illustrated) for example, is a positively increasing ramp. The signal C 2 acts upon the attenuation control circuit 320 such that it attenuates the signal A 1 , as can be seen by the resultant attenuated signal A 2 ′ illustrated in FIG. 4 f . Naturally, the attenuation of the signal A 1 to produce the attenuated signal A 2 ′ results in an attenuation of the signal FB
[0056] When the signal A 1 has beer attenuated by the attenuation control circuit 320 such that the value of FB equals that of Ref 1 , then the output of the comparator COMP reduces to its low state, as illustrated at time t 1 in FIG. 4 b.
[0057] As a result of the comparator returning to its low state, the output signal C 2 starts to reduce, which reduces the attenuation of the signal A 1 , which in turn increases the RMS value of the signal A 2 ′. Therefore, the signal FB increases such that it becomes greater than approximately Ref 1 , as illustrated at time t 2 in FIG. 4 b . This in turn causes the output from the comparator COMP to change to a high state, that in turn causes the signal C 2 to increase, which in turn causes the attenuator 210 to increase the attenuation of the signal A 1 and so on.
[0058] Therefore, he attenuation oscillates about its mean value, of say −6 dB for example. However, the circuit can be designed such that the oscillations or adjustments made to the attenuation are not prone to detection by the listener. One way of achieving this is to have relatively long time constants associated with the charging and discharging of the integrator INT. However, these time constants are such that the listener would neither detect any substantial difference in the output volume when the there is an increase/decrease in the signal A 1 or the oscillations in the signal A 2 ′.
[0059] [0059]FIG. 3 is just one example of how to automatically compensate for variations in the amplitude of an audio signal. The same can be achieved whether the system is analogue and/or digital. The implementation of the basic block diagram of FIG. 2 can be either: analogue; and/or digital, either hardware and/or by means of one or more Digital Signal Processing (DSP) algorithms and/or one or more software routines. These types of solutions will be known to those skilled in the art.
[0060] Although this invention has been described in connection with certain preferred embodiments, it should be understood that the present disclosure is to be considered as an exemplification of the principles of the invention and that there is no intention of limiting the invention to the disclosed embodiments. On the contrary, it is intended that all alternatives, modifications and equivalent arrangements as may be included within the spirit and scope of the appended claims be covered as part of this invention.
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A circuit for processing broadcast signals that includes circuitry for receiving and processing broadcast signals which contain audio information and providing a first audio signal, and circuitry for controlling the amplitude of a received second audio signal in response to a first control signal, and providing a third audio signal wherein the circuit further comprises circuitry that receives the first audio signal and provides the second audio signal for automatically limiting the amplitude of the first audio signal in response to at least one reference signal.
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FIELD OF THE INVENTION
This invention relates to the packaging of surgical sponges for presentation in the course of surgery, and particularly is directed to the packaging of strung medical sponges of the neurosurgical class.
BACKGROUND OF THE INVENTION
Medical sponges, and in particularly neurological sponges, commonly comprise a fibrous web, the fibers of which may be cotton, rayon, polyester or other synthetic or a combination of these. The fibers are bonded one to another by mechanical and/or chemical bonds, either with or without bonding additives. Neurological sponges, generally are of two types, strung and unstrung. In the strung sponges the absorbent web commonly is relatively small, ranging from about 1/4 inch square upwards. Most such sponges are less than about 3 inches in length and about 3 inches wide. The webs commonly are of about 1/32 inch thick. The strung sponges have attached thereto one or two strings, commonly a textile thread having one of its ends anchored to the web and the remainder of the string extending from the web to serve as a locator element. The unstrung sponges most often are larger than the strung sponges, ranging up to 6 inches in length and 3.5 inches in width. These sponges have no depending string attached thereto.
Neurological sponges are employed for absorbing blood and body fluids, but most frequently are saturated with saline or other solution and used to protect tissue or applied to the tip of a suction device for protecting the tissue when suction is applied.
In the course of a surgical procedure, the medical sponges are sterilized and supplied to the operating room table in units of 10 and are carefully counted after use. Because absorbent sponges very closely resemble tissue when the sponge is soaked with blood, it is at times difficult to distinguish the small blood-soaked sponge from the surrounding body tissue. Thus, it is common practice to attach to the sponge a locator string, commonly about 12 inches in length, of a textile material, for example, such string being kept at all times outside the surgical incision so that the presence of the sponge may be readily noted through observing the string. These sponges further are provided with a separate and distinct x-ray opaque element fixed to the sponge in a manner as prevents its dislodgement. In the event the count of the sponges following the surgery indicates that one or more of the sponges is missing and a search of the operating room fails to locate the missing sponge, while the patient is still in the operating room, a portable x-ray unit may be brought in and the surgical site x-rayed in an attempt to determine whether the sponge has been left inside the patient.
One of the major problems in the prior art packaging of medical sponges, particularly neurosurgical sponges, has been the ability to present the sponges individually. The problem of presenting these sponges is compounded by the presence of the long locator strings that are attached to the relatively small pads. Heretofore it has been proposed to mount the small sponges on a card with a string from the sponge passing through a slit, thence along one face of the card to engage one or more slits or slots until substantially the entire length of the string has been "wound" onto the card. These prior art packages have been difficult to grasp in the user's hand while attempting to remove one of the sponges, either the pad portion of the sponge or the string being disposed on the card in a position such that when the user grasps the card, the fingers of the hand contact either the string or the sponge thereby presenting opportunity for compromising the sterility of the sponge. Further, the slits or slots provided in the prior art cards are of a nature and/or location on the card that develops substantial and inordinate friction between the string and the card as the string is withdrawn through the slit. This friction may result in disengagement between the sponge and the string thereby rendering the sponge non-usable. Even though the friction may not be so great as to cause the pad to break away from its string, the force required between the pad and forceps in withdrawing the string from the slits is sufficiently great to dislodge fibers of the pad or even to tear the pad. Still further, the withdrawal of the strings from the slits or slots in the prior art cards is further compounded where the angle of direction change of the string as the string is wound onto the card is substantially acute, thereby increasing the friction between the string and the slit or slot as the string is pulled from the packaging. A further problem with the prior art devices is that the tail ends of the strings of the several sponges in the package are not anchored and tend to become entangled one with another and/or become entangled with other objects employed in the surgery; such as, forceps, retractors, etc.
In my copending application entitled SURGICAL SPONGE, there is disclosed a novel locator string for neurological sponges which application is incorporated herein by reference. My novel locator string comprises a plurality, e.g. 20 or more, monofilaments bundled together and helically wrapped with a yarn. This locator string is particularly sensitive to the friction encountered when withdrawing the string from the slits or slots of the prior art sponge packaging in that such friction can fray my new locator string under certain conditions. Further, my new locator string is slightly greater in cross-sectional area than the prior art textile strings thereby making it more difficult to withdraw from the prior art packaging.
In the prior art it has also been suggested that several, e.g. ten, sponges be arranged in a stack in or on the packaging. This arrangement has resulted in unacceptable entanglement of the strings in the immediate vicinity of the sponge pads so that withdrawal of a single sponge is further complicated.
It is therefore an object of the present invention to provide a package of strung medical sponges in which the several sponges are mounted individually in the packaging for ready withdrawal at the time of their use. It is another object of the present invention to provide a package of medical sponges in which the friction between the string and packaging is minimized. It is another object to provide a package of strung medical sponges which is readily sterilizable with either steam, radiation, or ethylene oxide gas.
SUMMARY OF THE INVENTION
In accordance with the present invention there is provided a package of strung medical sponges comprising a plurality of such sponges releasably held on a planar member such as a relatively stiff, self-supporting card. In one embodiment the card is of rectangular geometry with one of its ends having defined therein openings that pass through the thickness of the card and which are of a geometry and size sufficient to receive therethrough one of the strings of a strung sponge. Preferably this opening includes a slit that extends from the opening and opens outwardly of a first end of the card. A string is passed through such opening and caused to overlie the second, i.e. reverse, surface of the card and extend to and be received in a slot that opens outwardly of the right hand edge of the card, as the card is held in one's hand with the first major surface of the card facing the viewer. This first slot is of a geometry and size that is substantially greater than the cumulative cross-sectional area of all strings of all sponges received on the card. The strings are then caused to overly the face of the card and pass diagonally thereacross to engage a second slot in the left hand edge side margin of the card. The second slot is generally like the first slot and substantially a mirror image thereof. The strings passing through the second slot are then caused to overlie the reverse surface of the card with the tail of the strings being captured in a capture zone defined by a flap that is provided on the bottom margin of the card. As viewed in the manner described hereinabove, such flap is adapted to be folded back upon the reverse surface of the card to define such capture zone. In a preferred embodiment, the flap is of a dimension sufficient that it covers at least the closed end of the second slot to aid in retaining the strings that pass through such slot. Further, the flap may be provided with means such as a tab which is receivable in a further slot through the thickness of the card such that when the tab is received in such further slot, the flap is maintained in its folded position, thereby retaining the tails of the several strings in the capture zone defined between the flap and the back surface of the card.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a representation of a package of strung medical sponges and depicting various features of the present invention.
FIG. 2 is a plan view of one embodiment of a planar member suitable for use in the package of the present invention.
FIG. 3 is a plan view of the reverse side of the planar member of FIG. 2.
DETAILED DESCRIPTION OF THE INVENTION
With specific reference to the figures, in FIG. 1 there is depicted one embodiment of a planar member 10 which in the preferred embodiment comprises a rectangular section of cardboard. The planar member 10 includes a first end margin 12, a second end margin 14, these end margins being connected by a first side margin 16 and a second side margin 18. The planar member, i.e., card 10, is sufficiently stiff as to be self-supporting and to be readily grasped in the hand 20 by placing the user's fingers on a first major surface 26 comprising the reverse surface of the card as depicted in FIG. 1, along the second side margin 18, and by positioning the thumb on a second major surface 28, i.e. face, of the planar member to thereby grasp the second side margin of the card between the thumb and fingers. It is important to note in this respect that the present package provides ample room for the thumb and fingers of the user without engaging the string or pad portion of the sponges held on the card as will appear more fully hereinafter. Furthermore, the card is of sufficient stiffness as to resist substantial bending when grasped between the thumb and fingers as described. The card preferably is of a cellulose fiber composition, but may be of other materials such as a polymeric material. In the latter instance, the material may be of a foam or cellular construction or of a relatively more solid construction.
In a preferred embodiment, the card has a width dimension between the first and second side margins of preferably about 5". The card has an end-to-end dimension of about 7" including an additional length of about 11/4" which defines a flap 30. The thickness of the cardboard is not critical but preferably is relatively thin, e.g., less than about 1/64".
The first end margin 12 of the card 10 is provided with a plurality of openings 32 that extend through the thickness of the card. Notably these openings are of a geometry, e.g. preferably round, and a size that is sufficient to permit the ready passage of a string 74 therethrough without substantial frictional drag upon the string. In the depicted embodiment each of the openings 32 includes means defining a slit 34 extending from the opening 32 and opening outwardly at 36 of the first end margin 12. Still further, in the preferred embodiment the opening 36 to the slit 34 is preferably flared as indicated by the arrow 38 to provide guidance for moving the string 74 through the slit 34 and into the opening 32. In the preferred embodiment, there are ten openings 32 aligned substantially parallel to and across the width dimension of the first end margin 12 adjacent its edge 37. Preferably each of the openings 32 has associated therewith a numerical indicia for identifying the respective openings.
As seen in FIG. 1, there is a first slot 40 defined along the first side margin 16 of the card 10 and extends from its closed end 42 to open outwardly at 44 of the first side margin 16. In the depicted and preferred embodiment, this slot is located approximately equidistant between the first and second end margins 12 and 14. This slot is substantially larger in size than is required to receive ten of the strings 74 therein, thereby affording free movement of the strings into and out of the slot and/or sliding movement of the strings through the slot in the direction of the thickness of the planar member 10. Further, the preferred positioning of the first slot 40 provides for clearance for larger sponges mounted on the face 28 of the card without interfering with the winding of their strings on the card as described herein.
A second slot 46 is defined in the second side margin 18 of the card 10 with its closed end 48 directed inwardly of the card 10 and opening outwardly as at 50 of the second side margin 18. Like slot 40, slot 46 is of a size and geometry that permits ready access and removal of at least ten of the strings 74 through the slot without undue friction between the slot and the string. As shown in FIG. 1, in the preferred embodiment, the second slot 46 is disposed approximately two-thirds of the distance between the first and second end margins 12 and 14 and nearer the second end margin 14 than the location of slot 40. In a preferred embodiment, the second slot is located a linear distance from the edge 37 of the first end margin 12 of about 31/2 inches thereby providing adequate room to receive the user's fingers 22 and thumb 24 without contacting either the pad or the string. For similar reasons, and others the preferred width dimension is not less than about 2 inches.
The second end margin 14 of the planar member 10 includes a flap 52 which is foldable along a fold line 54 against the reverse surface 26 of the planar member 10 to define a capture zone 56 between the surface 26 and the flap 52 for the ends 58 of the strings 74 therebetween. In the depicted embodiment, the flap includes a tab 60 which is adapted to be received within a third slot 62 which extends through the thickness of the planar member 10 for maintaining the flap in the folded position.
Notably, the flap 52 is of a dimension such that it includes a portion 30 which overlies the closed end 48 of the second slot 46 and serves to capture the string 74 between the surface 64 of the flap 52 and the surface 26 of the planar member 10 at the location where the string passes through the slot 46, thereby enhancing the retention of the string within the slot against inadvertent falling out of the string, while not materially impeding the withdrawal of the string as the sponge is withdrawn from the card.
A plurality of strung medical sponges 70 are mounted on the card 10, such sponges being disposed in overlying relationship to the surface (face) 28 of the planar member 10 in the region of the first end margin 12. Only two sponges 70 and 72 are depicted in FIG. 1 for purposes of clarity but it will be recognized that the package normally includes ten such strung sponges. Each of the sponges 70 and 72 includes a string member 74 and 76 respectively. For purposes of clarity of description only, the positioning of the sponge 70 on the card 10 will be described, it being understood that the remaining sponges are similarly mounted in the package. Specifically, and with reference to FIG. 1, the string 74 of the sponge 70 is passed through the slit 34 and into the opening 32 to position the pad 80 of the sponge 70 in overlying relationship to the surface 28 and in a location close to the opening 32. Preferably, the sponge is substantially in contact with the margin of the opening 32 to limit its ability to move about relative to the opening 32 and/or the surface 28. As shown, the string 74 is caused to overlie the reverse surface 26 of the planar member 10 in a substantially straight line between the opening 32 and the closed end 42 of the slot 40, and enter into the slot 40, thence passing through the thickness of the card 10 and extend in a substantially straight line in overlying relationship to the surface 28 to enter the slot 46 and cause the tail 58 of the string 74 to pass through the thickness of the card 10 and enter the capture zone 56 defined by the flap 52. Each of the other sponges and their respective strings are similarly threaded upon the card 10 with the respective tails of the strings being contained and captured within the capture zone 56 so that these tails do not hang loose from the card to engage or become entangled with external objects. Further, the capturing of the tails in the capture zone maintains the tails against entanglement one with another so that these strings can be readily withdrawn individually from the capture zone.
In use, a surgeon or assistant grasps the card 10, as in their left hand. A sponge 70 commonly is withdrawn from the package by grasping it with forceps or the like and pulling on the sponge in a direction substantially perpendicular to the surface 28. As the sponge is pulled away from the surface 28, its string 74 is pulled through the slot 46, the slot 40, and the opening 32. It will be recognized that the size of the opening 32 and the relatively large size of the slots 40 and 46 permit substantially uninhibited movement of the string through these openings. Further, it is noted that as the string is threaded through the several openings and/or slots, the angle of directional change of the string at no time is an acute angle, but such directional change is of a substantial angle, e.g. at least about 90° or greater. This is important in reducing the friction exerted between the string and the card 10 at the points of directional change, for example at the slots 40 and 46 in particular.
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A package of strung medical sponges, particularly neurosurgical sponges comprising a plurality of sponges releasably held on a planar member such as a card which is self-supporting and suitable for grasping in one's hand. The strings of the sponges are threaded upon the card in a manner that permits the ready removal of the sponges one by one and which captures the tails of the strings to provided a neat and efficient package.
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This application is a continuation of application Ser. No. 07/796,279, filed Nov. 22, 1991 now abandoned, which is a continuation of Ser. No. 07/202,509 filed Jun. 2, 1988 now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to a vaccine that comprises liposomes adsorbed to aluminum hydroxide, the liposomes comprising lipid A and a molecule ("malarial antigen") that is capable of inducing an immune response against a malarial parasite in man or in an animal species. The present invention also pertains to a method of inducing an immune response in a mammal against a malarial parasite by injection of the above-described vaccine.
In the normal course of malarial infection, the parasitic malarial organism, in the form of a sporozoite, is transmitted to an animal host by the bite of a mosquito. Shortly thereafter, the sporozoite invades the host's liver where it replicates and produces numerous merozoites. These merozoites then invade the erythrocytes of the host.
In the development of a vaccine for protection of man and animals against malaria, therefore, it is desirable to produce a vaccine that can induce immunity against one of the life forms of the malarial parasite. For example, a vaccine can be developed against the sporozoites and thereby prevent invasion of the liver tissue and replication of the parasite. But in order for the induced immune response to be effective, the anti-sporozoite antibody titer must be sufficiently high (1) to maintain protective activity over a long period of time, preferably more than a year, and (2) to block sporozoite invasion of the liver within the short period of time after infection and before invasion of the liver.
Sporozoites are known to possess an antigenic surface protein known as a circumsporozoite ("CS") protein. The gene encoding the CS protein from Plasmodium falciparum has been cloned, and the amino acid sequence of this CS protein has been determined. It has been found that the middle portion of the CS protein comprises a region that has thirty-seven Asn-Ala-Asn-Pro tetrapeptides interspersed with four Asn-Val-Asp-Pro tetrapeptides. Peptides comprising various multiples of at least one of these two tetrapeptides are herein collectively referred to as "CS peptides."
Young et al, Science 228: 958-962 (1985), found that the highest antibody titer that could be induced in mice against the malarial parasite occurred when these animals were injected with CS peptides in admixture with complete Freund's adjuvant ("CFA"). When the mice were immunized with CS peptides adsorbed to aluminum hydroxide, without CFA, an intermediate level of antibody titer was obtained. Injection of one CS peptide, R16tet 32 , alone into mice induced very little immune response. It appears, therefore, that CRA is capable of enhancing the immune response of mice to a non-immunogenic CS peptide.
In the present description, "R16tet 32 " denotes a synthetic peptide that has (1) fifteen Asn-Ala-Asn-Pro tetrapeptide repeats and one Asn-Val-Asp-Pro tetrapeptide and (2) thirty-two amino acids derived from a tetracycline resistance gene. In like fashion, "R32tet 32 " and "R48tet 32 " denote peptides that are similar to R16tet 32 but that have two and three copies, respectively, of the sixteen tetrapeptides of R16tet 32 .
For purposes of vaccination in human, use of CFA is not desirable because of its severe side effects. Therefore, alternative adjuvants for stimulating the immunogenicity of antigens for use in man are sought. Liposomes have been used as an alternative adjuvant in animal systems. The ability of different liposomes to enhance immune response, however, has been variable.
For example, Allison and Gregoriadis, Nature 252: 252 (1974), reported that the use of negatively charged or neutral liposomes effectively induced a higher immune response to diphtheria toxoid ("DT") in mice, but that use of positively charged liposomes led to a weaker immune response than was obtained with the use of DT alone. In other studies in which other antigens were used, positively charged and negatively charged liposomes were found to be equally effective as adjuvants. See Heath et al., Biochem. Soc. Trans. 4: 129-133 (1976), and van Rooijen and van Nieuwmegen, Immunol. Commun. 9: 243-256 (1980). Accordingly it appears that whether liposomes can act as adjuvant varies from antigen to antigen.
Alving et al., Vaccine 4: 166-172 (1986) used liposomes comprising lipid A as adjuvants in inducing immunity in rabbits to cholera toxin ("CT") and to a synthetic CS peptide consisting of four Asn-Pro-Asn-Ala tetrapeptides conjugated to BSA. The authors found that the immune response to CT or to the synthetic malaria peptide was markedly enhanced by use of liposomes and lipid A, compared to similar liposomes lacking lipid A.
In contrast, Gerlier et al., J. Immunol. 131: 485-490 (1983), found in rats that liposomes comprising the same lipid A as used by Alving and his coworkers did not stimulate a greater immune response to antigens derived from cells infected with Gross virus. Hence, it again appears that the ability of liposomes with lipid A alone to serve effectively as adjuvants varies depending on the antigen and, perhaps, on the animal system used.
SUMMARY OF THE INVENTION
It is an object of the present invention, therefore, to provide a vaccine suitable for induction of immunity against malaria in man and/or animals.
It is also an object of the present invention to provide a vaccine comprising an adjuvant that is capable of enhancing the immune response to a malarial antigen in man and/or in animals.
It is another object of the present invention to provide a vaccine to a malarial antigen that does not require the use of a large quantity of such an antigen.
It is a further object of the present invention to provide a method for inducing immunity in humans or animals to a malarial parasite by use of a vaccine as described above.
In accomplishing these and other objects, there has been provided a vaccine comprising liposomes adsorbed to aluminum hydroxide, wherein said liposomes comprise lipid A and a malarial antigen.
In accordance with a further aspect of the present invention, there has been provided a method of inducing an immune response against a malarial parasite comprising the step of injecting a mammal with a vaccine as described above.
Further objects, features and advantages of the present invention will become apparent from the following detailed description. It should be understood, however, that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the immune response in Rhesus monkeys as a function of time after injection of
(a) R32tet 32 ("Ag alone"),
(b) R32tet 32 adsorbed to Amphojel® ("Ag+Amphojel") or
(c) liposomes that comprises R32tet 3 2 and lipid A, and that are adsorbed to Amphojel® ["L(Ag+LA)+Amphojel"].
Each of (a), (b) or (c) above is injected intramuscularly into a group of 4 monkeys at 0 and 4 weeks. Each dose comprises 40 μg of R32tet 32 in a volume of 0.5 ml. The immune response is expressed as units of ELISA activity or absorbance at 414 mn. Each data point represents the mean response of 4 monkeys injected in the manner indicated. The serum dilution employed was 1:400 dilution.
FIG. 2 shows the immune response of individual monkeys immunized as described under FIG. 1 above at 6 weeks after primary immunization.
FIG. 3 shows the time course of the immune response to liposomal vaccines in monkeys expressed as ELISA units. Each point represents the average ELISA units for 4 monkeys after subtraction of the prebleed values.
FIG. 4 shows the immune response of individual monkeys to liposomal R32tet 32 at 6 weeks after primary immunization.
FIG. 5 shows the immune response to liposomal R32tet 32 in monkeys at 6 weeks after primary immunization.
FIG. 6 shows the time course of the immuno response to liposomal vaccines in monkeys.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
It has been discovered that an unexpectedly large increase in antibody activity against a malarial antigen occurs in mammals injected with liposomes that comprise the antigen and lipid A and that are adsorbed to aluminum hydroxide. The enhancement in antibody activity can vary, but increases of 800-fold or more have been realized in accordance with the present invention.
In this regard, it is generally expected that a vaccine prepared in accordance with Good Manufacturing Practices ("GMP") prescribed by the U.S. Food and Drug Administration will be less potent than one prepared otherwise. This expectation holds true for the above-described vaccine. Yet, the reduction in potency of the vaccine within the present invention is much less than that of a vaccine that comprises the antigen alone adsorbed to aluminum hydroxide.
The ability, within the present invention, to use a nonpyrogenic fraction of lipid A or a nonpyrogenic amount of lipid A to stimulate an increase in antibody activity could not have been predicted.
It has further been found that Rhesus monkeys can be used as models for human treatment since, like humans, injection of a malarial antigen alone induce only low titers of antibody to the antigen. In contrast, injection of a small amount of a malarial antigen alone into rabbits and mice induces high antibody titers.
Within the present invention, a "malarial antigen" is an antigen that is capable of inducing an immune response against a malarial parasite in humans and/or in animals. Such an antigen can be unconjugated or can be a hapten conjugated to a carrier molecule.
Malarial antigens suitable for use in the context of the present invention include (1) a natural antigen of a malarial parasite or a malarial parasite-infected cell or a portion of such conjugated to a carrier or, (2) a synthetic protein or peptide that has the entire amino acid sequence of a natural malarial antigen or a portion thereof conjugated to a carrier.
Natural malarial antigens can be isolated by harvesting the parasite or parasite-infected cells from mosquitos and/or an infected host, lysing the parasites or cells, then isolating and purifying one or more antigens therefrom. For example, the following antigens are suitable for use in the present invention:
(a) a protein localized on the surface of sporozoites, prepared as described in Nussenzweig et al., J. Exp. Med. 156: 20 (1982), the contents of which are incorporated herein by reference;
(b) a 195 KD (kilodaltons) protein on the surface of merozoites or its cleavage products: proteins of 83 KD, 42 KD and 19 KD, prepared as described in Freeman and Holder, J. Exp. Med. 158: 1647 (1983), the contents of which are incorporated by reference;
(c) a 155 KD protein on the surface of P. falciparum-infected red blood cells, prepared as described in Perlmann et al., J. Exp. Med. 159: 1686 (1984), the contents of which are incorporated herein by reference;
(d) a small molecular weight antigen, about 15 KD to 19 KD from asexual blood stages of P. falciparum, prepared as described in International Patent No. WO 88/00597, the contents of which are incorporated herein by reference;
(e) a merozoite surface antigen, about 41 KD to 53 KD from asexual blood stages of P. falciparum, prepared as described in International Patent No. WO 88/00595.
A synthetic malarial antigen can be synthesized by a peptide synthesizer according to standard procedures if the amino acid sequence of such a protein is known, for example, in accordance to the method of M. B. Merrifield on a Beckman Peptide Synthesizer Model 990B. Since the amino acid sequence of the CS protein of P. falciparum has been established [see Dame et al., Science 225: 593-599 (1984), the contents of which are incorporated herein by reference], this protein or a portion thereof can be synthesized in this manner according to the known sequence. Suitable malarial antigens synthesized in this manner includes peptides of the formulas tyr-gly-gly-pro-ala-asn-lys-lys-asn-ala-gly-OH, asp-glu-leu-glu-ala-glu-thr-gln-asn-val-tyr-ala-ala-NH 2 , and tyr-ser-leu-phe-gln-lys-glu-lys-met-val-leu-NH 2 , prepared as described in U.S. Pat. No. 4,735,799, the contents of which are herein incorporated by reference.
Alternatively, a synthetic malarial antigen can be produced by recombinant techniques as described in "Guide to Molecular Cloning Techniques" in 152 METHODS IN ENZYMOLOGY, pp. 113-129, Berger and Kimmel ed. (Academic Press, Inc. 1987), the contents of which are incorporated herein by reference, and as described in U.S. Pat. No. 4,707,357, the contents of which are corporated herein by reference.
In a preferred embodiment, a malarial antigen is obtained from bacterial or yeast cells, and comprises several repeats of a portion of the amino acid sequence of a surface antigen of a malaria parasite, prepared as described, for example, in Young et al., Science 228: 958-962 (1985), the contents of which are hereby incorporated by reference.
In general, a bacterial plasmid comprising the DNA sequence of a gene encoding a malarial antigen (hereafter "malarial-antigen DNA") can be treated with a restriction endonuclease to excise all or a fragment thereof. This malarial-antigen DNA fragment can be then joined by DNA ligase to another endonuclease-treated bacterial plasmid containing the appropriate genes for expression of the antigenic malaria protein or peptide, and an appropriate marker gene.
The marker gene can be any gene that permits selective growth of only those transformed bacteria carrying the desired plasmids. For example, a marker gene can be a gene conferring the ability to utilize a certain element or compound as nutrient or can be a gene conferring antibiotic resistance to the organism, e.g., a tetracycline resistance ("Tet r ") gene. Propagation of those bacterial cells that carry the malarial-antigen DNA in their plasmids would yield the desired recombinant molecules that can serve as malarial antigens.
Use of recombinant DNA techniques to produce malarial antigens can result in the production of plasmids of varying lengths, e.g., pR16tet 32 , pR32tet 32 and pR48tet 32 , that encode the peptides R16tet 32 , R32tet 32 and R48tet 32 , respectively, the peptides having the definitions given above. Peptides that are smaller in size, e.g., R16tet 32 , can be used as a hapten to produce a malarial antigen after conjugation to larger molecules such as bovine serum albumin or other albumins. Another malarial antigen synthesized by recombinant technique is an antigen designated FSV-2 made in E. coli and comprises the amino acid sequence of a portion of the CS protein of P. falciparum, as follows:
wherein A denotes alanine, C denotes cysteine, D denotes aspartic acid, E denotes glutamic acid, F denotes phenylalanine, G denotes glycine, H denotes histidine, I denotes isoleucine, K denotes lysine, L denotes leucine, M denotes methionine, N denotes asparagine, P denotes proline, Q denotes glutamine, R denotes arginine, S denotes serine, T denotes threonine, V denotes valine, and W denotes tryptophan. See also International Patent No. WO 87/06939, the contents of which are incorporated herein by reference.
Immunogenic polypeptides comprising the tetrapeptide repeats of the P. falciparum circumsporozoite protein include RNS1 81 polypeptides. R32NS1 81 has been found to be highly effective for causing immune response in mammals to P. falciparum sporozoites. R32NS1 81 comprises the R32 antigenic sequence fused to 80 N-terminal amino acids of NS1. In the fusion, R32 is fused to the second amino acid of NS1; at the C-terminus, amino acid 81 of NS1 is fused to a sequence of -Leu-Val-Asn. Thus the sequence is:
N-Asp-Pro-(Asn-Ala-Asn-Pro) 15 -(Asn-Val-Asp-Pro)-(Asn-Ala-Asn-Pro) 15 -Asn-Val-NS1 81 -C
wherein the term "NS1 81 " used above includes the residues Leu-Val-Asn fused at the C-terminus.
To prepare vaccine within the present invention, liposomes comprising lipid A which have been previously dried, as described in more detail below, are mixed and rehydrated in the presence of a malarial antigen and a medium suitable for injection, e.g., Dulbeccos's phosphate buffered saline lacking CaCl 2 and MgCl 2 .6H 2 O ("DPBS, GIBCO Laboratories, Grand Island, N.Y.). The amount of antigen thereby encapsulated can be determined by Lowry protein assay. The preparation is then diluted to a predetermined concentration in DPBS.
The dose of antigen suitable for injection can be determined via routine experimentation. For example, by injecting various groups with different doses of the alum-adsorbed, liposome/lipid A-encapsulated antigen, and monitoring the immune response of each group to determine what dosage induces the highest anti-malarial antibody titer for the longest period of protection. Preferably, the amount of protein or peptide antigen to be injected is less than about 800 μg, and more preferably in the range of about 30 to about 100 μg per dose. The number of doses of vaccines to inject also can be determined by routine experimentation. Typically, the dose can vary depending upon the level of rotection desired. For example, after an initial injection at 0 week and a booster at 4 weeks, further booster doses can be injected at monthly, semi-yearly or yearly intervals.
The malarial antigen prepared above can be first mixed with liposomes comprising lipid A for encapsulation and later mixed with aluminum hydroxide for adsorption, as described in more detail below. The vaccine prepared in this manner can be administered via any generally accepted mode of vaccination. For example, it can be taken orally or injected subcutaneously, intramuscularly, intravenously, intradermally or intraperitoneally.
Exemplary of the commercially-available aluminum hydroxide formations that can be used is Amphojel®, an aluminum hydroxide oral antacid which is suitable for animal use. More preferably, especially for human use, is an aluminum hydroxide absorptive gel (hereafter "Alum"), prepared in accordance with the Good Manufacturing Practices (GMP) prescribed by the U.S. Food and Drug Administration. The aluminum hydroxide to be used for adsorption of liposomes can be diluted in PBS. It is to be noted that, consistent with the general observation that the formulation of materials in accordance with GMP causes marked reduction of potency, the potency of a vaccine of the present invention is found to be reduced when Amphojel® is replaced with alum.
Lipid A is a lipoidal constituent of lipopolysaccharide ("LPS") from Gram-negative bacteria, e.g., E. coli, Salmonella and Shigella, and can be prepared in the manner described in Alving et al., 2 LIPOSOME TECHNOLOGY 157-175, G. Gregoriadis, ed. (CRC Press 1984). In essence, LPS is prepared by phenol-extraction or by trichloroacetic acid treatment of such bacterial cells. Lipid A can also be purchased from available commercial sources, e.g., Calbiochem-Behring (La Jolla, Calif.), List Biological Laboratories, Inc. (Campbell, Calif.) and Ribi Immunochem Research, Inc. (Hamilton, Mont.). LPS is similarly available from commercial sources, e.g., Difco (Detroit, Mich.), List Biological Laboratories, Inc. and Ribi Immunochem Research, Inc.
For extraction of lipid A from LPS, the LPS is heated in a boiling water bath for about two hours in about 1% acetic acid in an amount of 10 mg of LPS per ml. The precipitate formed is washed three times with distilled water by centrifugation at 4° C. and then lyophilized. To purify the lipid A so obtained, an aqueous solution of about 0.5% triethylamine ("TEA") is used for solubilization of lipid A in the water phase. This solution is allowed to stand for about 10 to 30 minutes. The phases are separated, with or without centrifugation at about 12,000×g for about 10 minutes. The resulting purified lipid A is chloroform soluble and may be analyzed for phosphate content. In general, about 1 μg of the chloroform-soluble lipid A from E. coli, strain 0111 LPS (from Difco) contains about 0.3 nmol of phosphate, and 1 μg from Salmonella lipid A contains about 0.7 nmol of phosphate.
Phospholipids are used for preparing the liposomes employed in the context of the present invention. In contrast to other studies, it has been found that liposomes carrying a net positive charge or a net negative charge, or that are neutral, are all effective as adjuvants in the present invention. Accordingly, the liposomes to be used herein can carry a net positive charge, a net negative charge or can be neutral. Dicetyl phosphate can be employed to confer a negative charge on the liposomes, and stearylamine can be used to confer a positive charge on the liposomes. Preferably, the phospholipids to be used are diacylglyerols in which at least one acyl group comprises at least twelve carbon atoms, preferably between about fourteen to about twenty-four carbon atoms. It is also preferred that at least one head group of the phospholipids, i.e., the portion of the molecule containing the phospho-group, is a phosphocholine, a phospho-ethanolamine, a phosphoserine or a phosphoinositol.
Lipids suitable for use in the context of the present invention can be purchased from commercially sources. For example, dimyristoyl phosphatidylcholine ("DMPC") can be purchased from Sigma Chemical Co.; dicetyl phosphate ("DCP") is available from K and K Laboratories (Plainview, N.Y.); cholesterol ("Chol") from Calbiochem-Behring; dimyristoyl phosphatidylglycerol ("DMPG") and other lipids from Avanti Polar Lipids, Inc. (Birmingham, Ala.) Stock solutions of lipids in chloroform or chloroform/methanol can be stored at about -20° C. Preferably, chloroform is used as the only solvent since it is more readily evaporated than methanol.
Phospholipids from natural sources, such as egg or soybean phosphatidylcholine, brain phosphatidic acid, brain or plant phosphatidylinositol, heart cardiolipin, and plant or bacterial phosphatidylethanolamine are preferably not used as the primary phosphatide because of the instability and leakiness of the resulting liposomes.
The liposomes to be used in accordance with the present invention can comprise lipids in any molar ratio and can (but need not) contain cholesterol. Preferably dimyristoyl phosphatidylcholine, dimyristoyl phosphatidylglycerol and cholesterol, respectively, are combined in molar ratios of about 0.9:0.1:0.75, respectively.
Liposomes used herein can be made by different methods. The size of the liposomes varies depending on the method used for making them. A liposome in solution is generally in the shape of a spherical vesicle having one or several concentric layers of lipid molecules each of which is represented by the formula XY wherein X is a lipophobic-hydrophilic moiety and Y is a lipophilic-hydrophobic moiety. In solution, the concentric layers are arranged such that the hydrophilic moiety remains in contact with an aqueous phase. For example, when aqueous phases are present both within and without the liposome, the lipid molecules will, at a minimum, form a bilayer, known as a lamella, of the arrangement XY-YX.
Liposomes within the present invention can be prepared in accordance with known laboratory techniques. In one preferred embodiment, liposomes can be made by mixing together the lipids to be used, including lipid A, in a desired proportion in a container, e.g, a glass pear-shaped flask, having a volume ten times greater than the volume of the anticipated suspension of liposomes. Using a rotary evaporator, the solvent is removed at approximately 40° C. under negative pressure. The vacuum obtained from a filter pump aspirator attached to a water faucet may be used. The solvent normally is removed within about 2 to 5 minutes. The composition can be dried further in a desiccator under vacuum. The dried lipids are generally discarded after about 1 week because of its tendency to deteriorate with time.
The dried lipids can be hydrated at approximately 30 mM phospholipid in sterile, pyrogen-free water by shaking until all the lipid film is off the glass. The aqueous liposomes can be then separated into aliquots, each placed in a vaccine. vial, lyophilized and sealed under vacuum.
In the alternative, liposomes can be prepared in accordance with other known laboratory procedures, e.g., the method of Bangham et al., J. Mol. Biol. 13: 238-52 (1965), the contents of which are incorporated herein by reference; the method of Gregoriadis, as described in "Liposomes" in DRUG CARRIERS IN BIOLOGY AND MEDICINE, pp. 287-341 (G. Gregoriadis ed. 1979), the contents of which are incorporated herein by reference; the method of Deamer and Uster as described in "Liposome Preparation: Methods and Mechanisms" in LIPOSOMES (M. Ostro ed. 1983), the contents of which are incorporated by reference; and the reverse-phase evaporation method as described by Szoka, Jr. and Papahadjopoulos, in "Procedure for Preparation of Liposomes with Large Internal Aqueous space and High Capture by Reverse-Phase Evaporation," Proc. Natl. Acad. Sci. USA 75: 4194-98 (1978). The aforementioned methods differ in their respective abilities to entrap aqueous material and their respective aqueous space-to-lipid ratios.
The lyophilized liposomes prepared in the above-described manner can be rehydrated and reconstituted in a solution of the malarial antigen and diluted to an appropriate concentration with an suitable solvent, e.g., DPBS. The mixture is then vigorously shaken in a vortex mixer. Unencapsulated antigen can be removed by centrifugation at 29,000×g and the liposomal pellets washed. The washed liposomes can be suspended at an appropriate total phospholipid concentration, e.g., about 20 to about 40 mM. The amount of malarial protein antigen encapsulated can be determined in accordance with the method of Lowry.
After determination of the amount of antigen that is encapsulated in the liposome, the liposomes can be diluted to about 30 μg of antigen per 0.5 ml and can be either bottled immediately or incubated with alum, at approximately 1.0 mg/ml of aluminum, for 1 hr at room temperature, before bottling in vaccine vials, at 3 ml per vial, and storing at 4° C. until use.
For incorporation of lipid A into the liposomes in accordance with the present invention, lipid A can be added to the flask together with the other lipids used for making up the liposomes, i.e., DMPC, Chol, DCP, and all of the lipids can be dried together. In one preferred embodiment, lipid A from S. minnesota R595, herein designated "native lipid A," can be included in the liposomes at a concentration of about 0.2 nmoles (hereafter "lipid A-0.2") to about 20 nmoles (hereafter "lipid A-20") of lipid A phosphate per μmol of liposomal phospholipid. In another preferred embodiment, nontoxic monophosphoryl lipid A (hereafter "MP lipid A-0.5") can be used in place of native lipid A at 0.5 nmoles of lipid A phosphate per μmol of liposomal phospholipid. "Monophosphoryl lipid A" as used herein denotes a monophosphoryl fraction isolated from native lipid A that has reduced pyrogenicity when tested in rabbits via established techniques.
Antibody production in response to injection of a vaccine of the present invention can be monitored by enzyme-linked immunosorbent assays (herein "ELISA"), which can be carried out in accordance with established laboratory techniques. In particular, wells of polystyrene microtiter plates can be each coated with 0.1 μg of R32tet 32 in 0.01 M PBS, pH 7.4. Approximately 18 hr later, the contents of the wells can be aspirated, and the wells filled with blocking buffer, i.e., about 1.0% BSA, 0.5% casein, 0.01% thimerosal and 0.005% phenol red in PBS, and held for 1 hr at room temperature. Sera to be tested, e.g. rabbit sera, can be diluted in blocking buffer, and aliquots of each dilution added to triplicate wells. After a 2-hr incubation at room temperature, the contents of the wells are aspirated, and the wells washed three time with PBS-Tween 20. About 50 μg of horseradish peroxidase conjugated to, e.g., goat-anti-rabbit immunoglobulin G (IgG Bio-Rad Laboratories, Richmond, Calif.) which is diluted 1:500 with 10% heat-inactivated human serum in PBS is then added to each well. After 1 hr, the contents of the wells are aspirated, the wells washed three times with PBS-Tween 20, and 150 μl of peroxidase substrate in buffer is then added to each well. The absorbance at 414 nm can be determined 1 hr later with an ELISA plate-reader device like the TITERTEK MULTISKAN® (Product of Flow Laboratories, Inc., McLean, Va.).
The present invention is further described below by reference to the following examples.
EXAMPLE 1
Clinical use of a malaria sporozoite vaccine, comprising R32tet 32 , for immunization in man and challenge thereof with P. falciparum.
Fifteen healthy male volunteers, aged 22-50, who were free from a history of (1) malaria, (2) cardiac, hematological, renal, hepatic or immunological illness, (3) immunosuppressive medication, and (4) preexisting antibodies to blood-stage P. falciparum parasites, as determined by immunofluorescent assay, or to R32tet 32 , as determined by an ELISA, were injected with a malarial antigen, R32tet 32 , as described in Ballou et al, Lancet, vol. i, pp. 1277-1282 (June, 1987), the contents of which are hereby incorporated by reference. Two such men served as non-immunized controls for the challenge part of the study.
R32tet 32 is a recombinant molecule comprising a sequence of 32 amino acids identical to that found in a portion of the CS protein of P. falciparum and a sequence comprising the first 32 amino acids of a tetracycline resistance gene found in a E. coli plasmid. The sequence of R32tet 32 is identified as follows:
MDP(NANP).sub.15 NVDP(NANP).sub.15 NVDPtet.sub.32
where M=methionine, D=aspartic acid, P=proline, N=asparagine, A=alanine, V=valine, and tet 32 =the first 32 amino acids encoded by the E. coli tetracycline resistance gene. The vaccine, designated herein as FSV-1, took the form of single-dose ampules of sterile R32tet 32 in aqueous saline containing 0.5 mg Al 3+ (as aluminum hydroxide gel) per 0.5 ml dose. Thiomersal was added as a preservative. FSV-1 was stored at 4° C. and protected from light before administration. The vaccine was prepared at five different concentrations: 10 μg, 30 μg, 100 μg, 300 μg and 800 μg R32tet 32 per 0.5 ml dose.
The vaccine was given intramuscularly to three volunteers for each of five doses. Volunteer received primary immunization at week 0 and were boosted with identical doses at weeks 4 and 8. Fifty weeks after primary immunization, six of these volunteers received a fourth identical dose. Volunteers were observed for immediate toxic effects for twenty minutes after immunization. Twenty-four and forty-eight hours later, they were examined for evidence of fever, local tenderness, erythema, warmth, induration and lymphadenopathy, and were asked about complaints of headache, fever, chills, malaise, local pain, nausea and joint pain. Before each vaccine dose, blood and urine samples were taken for full laboratory examination. Complete blood count and serum chemistry profiles were rechecked two days after each vaccine dose.
Serum samples were taken from each subject one week after the first dose, then every two weeks for sixteen weeks, and at the time of sporozoite challenge. Previously characterized human sera from malaria-endemic regions of Indonesia and western Kenya were used for comparison. Serum was separated from blood that had clotted overnight at 4° C. and stored at -70° C. until assay.
An ELISA for CS antibodies was carried out in accordance with established laboratory procedures. The test antigen used for the ELISA was R32LR: MDP(NANP) 15 NVDP(NANP) 15 NVDPLR, a purified recombinant construct that contained only the first 2 amino acids encoded by the E. coli tetracycline resistance gene. Horseradish peroxidase conjugated to rabbit antihuman-IgG (heavy and light chains) was used to detect antibodies. Assays were run in triplicate and the mean absorbance and standard deviation were calculated for each dilution. Background values at a given dilution were determined with preimmunization samples and defined as an optical density less than the mean plus two standard deviations of the week 0 serum sample's optical density for all volunteers.
Serum samples obtained from the volunteers were assayed for IgG, IgM and IgA antibodies to R32LR by ELISA as described above. IgE antibodies reactive with R32tet 32 or R32LR were measured by ELISA with biotin-conjugated goat anti-human-IgE as second antibody and detected with streptavidin/horseradish-peroxidase complex. Human IgE myeloma protein was used to prepare a standard curve.
Three weeks after the volunteers had received a fourth dose of FSV-1, six immunized and two non-immunized control volunteers were challenged with the chloroquine-sensitive NF54 strain of P. falciparum by allowing 5 mosquitos with a mean salivary gland infection rate of 3.3 to feed. Beginning on day 5 after mosquito feeding, daily thick-blood films were examined for parasites.
The vaccine was found to be well-tolerated at all five doses. There were no episodes of fever, chills, malaise, headache, nausea, or joint pain. Minor pain associated with the injection of vaccine occurred in seven of nine volunteers receiving doses of 100 μg or greater. The injection site was slightly tender in eight of fifteen volunteers after at least one dose of vaccine, including all those receiving 300 μg or 800 μg doses. In no case did these complaints limit function or persist more than 48 hr.
Antigen-specific IgG was detected 2 weeks after the primary immunization and was dose dependent between 100 μg and 800 μg of R32tet 32 . Twelve of fifteen (80%) volunteers had antibody titers of 1:50 or greater. Maximum antibody responses were sustained for 2 to 3 weeks and disappeared with a half-life of about 28 days. The titer rose significantly after repeated doses in only one volunteer, who received the 800 μg dose. His antibody levels were similar to those of the highest-titer sera yet observed from malaria-endemic populations. Immunoglobulin class determinations revealed IgM, IgA, and IgG antibodies to the antigen in all positive serum samples, with IgG antibodies predominating.
About 50 weeks after the first immunization, six volunteers received a fourth dose of FSV-1. Antibody to CS epitopes increased above baseline in four subjects, but all titers were below the maximum titers achieved during the primary immunization. These volunteers and two non-immunized control subjects were challenged by the bite of P. falciparum-infected mosquitos 3 weeks after booster dose. Protection appeared to correlate with antibody levels. Parasitaemia was not detected in the volunteer with the highest antibody response and among the subjects who became parasitaemic the incubation and prepatent periods were long in the two subjects with higher antibody titers. The clinical manifestations of malaria were not modified in the two volunteers who had delayed parasitaemia.
EXAMPLE 2
Use of liposomes, lipid A and Amphojel® to enhance the immune response of monkeys to a synthetic malaria sporozoite antigen.
Four Rhesus monkeys per group for a total of 3 groups were each immunized at 0 and 4 weeks with 40-μg doses of
(a) R32tet 32 either as free antigen alone ("Ag"),
(b) Amphojel®-adsorbed antigen (hereafter "Ag+Amphojel"), or
(c) Amphojel®-adsorbed liposome containing encapsulated antigen and lipid A [hereafter "L(Ag+LA)+Amphojel"].
All injections were done intramuscularly, and each dose was in a volume of 0.5 ml.
The liposomes that were used herein for immunization comprises DMPC, DMPG and Chol, in mole ratios of about 0.9:0.1:0.75. When present, lipid A was included in the liposomes at a concentration of 20 nmol of lipid A phosphate per μmol of phospholipid.
Liposomes were prepared as described above. The lipid mixture in chloroform was dried under vacuum in pear-shaped flasks. After addition of a small quantity of acid-washed 0.5 mm glass beads, the liposomes were swollen in solutions of R32tet 32 diluted in 0.15M NaCl by 2 min of vigorous shaking in a vortex mixer. Unencapsulated antigen was removed by centrifugation at 12,000 to 15,000×g for 10 min at 20° C., and the liposomal pellets were then washed in 0.15 M NaCl by centrifugation as above. The washed liposomes were suspended in 0.15 M NaCl at a total phospholipid concentration of 20 mM. Liposomes prepared in this manner are adsorbed to Amphojel® as described above.
The antigens to be adsorbed can be mixed with aluminum hydroxide and the mixture can be allowed to stand at 4° C. for about 12 hr. After about 12 hours, sufficient supernatant is discarded so as to yield an aluminum hydroxide concentration of about 0.80 mg to about 1 mg/ml of and an antigen concentration of about 30 μg per 0.5 ml per dose. Results are shown in FIGS. 1 and 2.
Each data point in FIG. 1 represents the mean of all four monkeys in each group. The serum dilution shown is 1:400. This Figure shows that Ag alone was not immunogenic and did not elicit any significant antibody activity. In contrast, about a 2-fold increase in antibody activity was observed at 6 weeks after primary immunization when Ag was combined with Amphojel®,and about a 3-fold increase in antibody activity was observed when Ag was encapsulated in liposomes containing lipid A and adsorbed to Amphojel®. Comparison between the latter two groups shows about a 50% increase in antibody activity in the last-mentioned group.
FIG. 2 shows that all 4 monkeys in the Ag+Amphojel and the [L(Ag+LA)+Amphojel] groups produced high titers of antibodies but none of the monkeys in the Ag group produced antibodies in any significant amounts.
EXAMPLE 3
Use of liposomes, lipid A and aluminum hydroxide, manufactured in accordance with GMP, to enhance the immune response of monkeys to a synthetic malaria sporozoite antigen.
Four monkeys per group were immunized at 0 and 4 weeks with 30 μg of R32tet 32 which were either
(a) adsorbed with alum ("FSV-1"),
(b) encapsulated in liposome lacking lipid A ["L(Ag)"],
(c) encapsulated in liposomes lacking lipid A and then adsorbed with alum ["L(Ag)+Alum"],
(d) encapsulated in liposomes containing a nonpyrogenic dose of native lipid A and then adsorbed with alum ["L(Ag+Lipid A-0.2)+Alum"],
(e) encapsulated in liposomes containing a nonpyrogenic dose of monophosphoryl lipid A and then adsorbed with alum ["L(Ag+MP Lipid A-0.5)+Alum"] or
(f) encapsulated in liposomes containing a pyrogenic dose of native lipid A and then adsorbed with alum ["L(Ag+Lipid A-20)+Alum"].
The foregoing vaccines were prepared as described above and the results are shown in FIGS. 3-6. Each point represents the average ELISA activity for 4 monkeys after subtraction of prebleed activity.
FIG. 3 shows the antibody activity induced in undiluted sera of monkeys as a function of time after primary immunization. At 6 weeks after primary immunization, L(Ag)+Alum increased antibody response in monkeys by about 2 to 3-fold as compared to monkeys injected with FSV-1. In comparison, L(Ag+Lipid A-20)+Alum increased antibody response by about 100-fold as compared to monkeys injected with FSV-1.
FIG. 4 shows the ELISA activity of individual monkeys 6 weeks after primary immunization, as represented by individual bars, after substraction of prebleed values. This Figure shows that at a serum dilution of 1:400, none of the monkeys injected with FSV-1 exhibited antibodies to R32tet 32 . In contrast, all the monkeys injected with [L(Ag+Lipid A-20)+Alum] were immunized, that is, all had antibody titer showing absorbance at 414 nm of greater than 0.5 (A 414 >0.5). When lipid A-0.2 was used, 2 of the 4 monkeys injected exhibited high antibody titers, i.e. A 414 >0.5. The highest antibody response was observed with monkeys immunized with a vaccine within the present invention.
FIG. 5 shows the immune response of monkeys at 6 weeks after primary immunization. Each data point in FIG. 5 represents the mean values of the 4 monkeys in each group. This Figure shows, e.g., that at a serum dilution of 1:800, when antibody response in monkeys injected with FSV-1 was negligible, monkeys injected with L(Ag+Lipid A-20)+Alum still exhibited a high antibody response. Therefore, the latter vaccine can be said to induce an increase in antibody response of greater than 800-fold.
The increase in antibody response of the L(Ag+Lipid A-20)+Alum vaccine can even be said to be greater than 3200-fold since at 1:3200 dilution, monkeys injected with FSV-1 showed no antibody activity, whereas monkeys injected with L(Ag+Lipid A-20)+Alum still exhibited an antibody activity of >0.5 ELISA units.
FIG. 5 further shows that at 1:800 serum dilution, monkeys injected with L(Ag+MP Lipid A-0.5)+Alum, a vaccine comprising a nonpyrogenic preparation of Lipid A, exhibited an antibody response of >0.5 ELISA unit while monkeys injected. with FSV-1 showed negligible antibody activity. The former vaccine, therefore, is also able to induce approximately a 800-fold increase in antibody activity in monkeys. Similarly, FIG. 5 shows that the vaccine L(Ag+Lipid A-0.2)+Alum, comprising a nonpyrogenic dose of Lipid A was able to induce an approximate 200-fold increase in antibody activity.
FIG. 6 shows the time course of immune response at two serum dilutions, 1:50 and 1:200.
The large increases in antibody response obtained in this study are entirely unexpected especially in view of only about a 50% increase shown in FIG. 1 of Example 2 above, where monkeys were injected with higher amounts of antigen and the vaccines were made not in accordance with GMP. The ability of a nonpyrogenic portion or dose of lipid A to act as adjuvant is also unexpected.
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Vaccines for the induction of immunity to malaria, based on aluminum hydroxide-treated, lipid A- and malarial antigen-containing liposomes, are described. Vaccines of this sort are useful in both humans and animals.
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REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent Application Ser. No. 60/882,305, filed Dec. 28, 2006, by the inventors named in this application, the entire content of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to the prevention of infection and, more particularly, to the provision of methods and devices for inhibiting exposure to microbes and infection.
[0003] Changes in modern lifestyle have occurred which would have been almost unimaginable even a century ago. An adverse consequence of some of these changes has been an increased exposure to harmful microbes. For example, travel between continents is a commonplace experience for many individuals. Unfortunately, increased ease of travel facilitates transfer of potentially disease-causing microbes which were historically limited by geography. Another change is the fact that individuals are surviving bacterial infections, which were previously commonly fatal, due to the advent of antibiotics. People are not the only entities that are changing and adapting. Adaptation by microbes, fueled by today's modern antibiotic prescribing practices has resulted in the appearance of many antibiotic-resistant strains.
[0004] The combination of increased exposure to harmful microbes and the more frequent encounter with antibiotic-resistant organisms contributes to a continuing need for antibiotic devices and methods. Effective antibiotic devices and methods are required to decrease exposure to microbes during daily activities in public places as well as in private homes. In addition, reduced exposure to microbes is important in medical and dental settings, such as care facilities, treatment rooms, surgical suites and nursing stations.
SUMMARY OF THE INVENTION
[0005] Devices and methods are provided for inhibiting exposure to microbes and infection according to the present invention.
[0006] The present invention provides an antimicrobial device, including a device body having a first electrically conductive element having a first external surface and a second electrically conductive element having a second external surface, the second element being electrically isolated from said first element, a first metal component containing an antimicrobial metal disposed on the first external surface of the device body, a power source for supplying current to the first metal component, the first and second elements being adapted to being electrically connected to each other by an object external to the antimicrobial device, whereby current flows through the antimicrobial metal causing metal ions to flow from the antimicrobial metal toward the object.
[0007] The antimicrobial device can be any object used in everyday life, including those specifically identified hereinbelow.
[0008] The present invention also provides a method for inhibiting exposure to microbes and infection. The method includes the steps of providing a device having a device body including an antimicrobial metal having a first external surface and an electrically conductive element having a second external surface, the second element being electrically isolated from the device body, providing a power source for supplying current to the device body, and configuring the device body and the electrically conductive element to cause the device body and the electrically conductive element to be electrically connected to each other by an object external to the antimicrobial device when the device is in normal use, whereby current flows through the antimicrobial metal causing metal ions to flow from the antimicrobial metal toward the object.
BRIEF DESCRIPTION OF THE DRAWING
[0009] FIG. 1 is a schematic circuit diagram of at least a portion of an electrical circuit included in a device provided by the present invention;
[0010] FIG. 2 is a view of an embodiment of an antimicrobial doorknob device provided by the present invention;
[0011] FIG. 3 is a “killing curve” showing the killing rate of an embodiment of the present invention associated with S. aureus;
[0012] FIG. 4 is a “killing curve” showing the killing rate of an embodiment of the present invention for Escherichia coli;
[0013] FIG. 5 is a cross-sectional view of a portion of a further embodiment provided by the present invention;
[0014] FIG. 6 is a cross-sectional view of a portion of a further embodiment provided by the present invention;
[0015] FIG. 7 shows a further embodiment provided by the present invention;
[0016] FIG. 8 shows a further embodiment provided by the present invention; and
[0017] FIG. 9 shows a further embodiment provided by the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] Broadly described, a device for inhibiting exposure to microbes and infection according to the present invention includes at least two portions, described herein as a first element and a second element. Each of these portions has an external surface. At least a first antimicrobial metal component is disposed on the external surface of the first element. Optionally, a second antimicrobial metal component is disposed on the external surface of the second element.
[0019] A power source powers a device according to the present invention. Such a power source may be any suitable power source, illustratively including line current or an electrical cell such as an electrochemical cell or a solar cell. Examples include a battery, a capacitor, and connection to external AC. One terminal of the power source is in electrical communication with the first element and the first antimicrobial metal component. The second terminal of the power source is in electrical communication with at least the second element and optionally with the second antimicrobial metal component, if present.
[0020] The first and second elements and the first and second antimicrobial metal components are electrically insulated from each other by at least one insulator. The insulator prevents current flow from the first element and/or first antimicrobial metal component to the second element and/or second antimicrobial metal component without completing a circuit through at least the first antimicrobial metal component and an electrical conductor in contact with the surface of the device.
[0021] Optionally included in electrical communication with a device according to the present invention is circuitry adapted to modulate a current from the power source. For example, a resistor, a switch, a signal receiver, a relay, a signal transmitter, transformer, a sensor, or a combination of these or other such components and connectors may be included, optionally configured as a circuit board arrangement. In a preferred embodiment, all or part of the circuitry adapted to modulate an electrical current is housed in a cavity in one or more portions of the device.
[0022] A metal component includes an antimicrobial metal. An antimicrobial metal is one which inhibits one or more microbes, such as bacteria, protozoa, viruses, and fungi. An antimicrobial metal may be microbiocidal or microbiostatic.
[0023] Antimicrobial metals include transition metals and metals in columns 10-14 of the periodic table. Such metals illustratively include silver, gold, zinc, copper, cadmium, cobalt, nickel, platinum, palladium, manganese, and chromium. In certain embodiments, lead and/or mercury may be included in amounts not significantly toxic to a user. Highly preferred is a metal component containing an antimicrobial metal which generates metal ions in response to application of current to the metal component.
[0024] A metal component contains an amount of an antimicrobial metal, the amount in the range of 1%-100% by weight of the total composition of the metal component, although in particular embodiments, lower amounts may be included. In general, a metal component included in an inventive device contains an amount of an antimicrobial metal in the range of about 1 nanogram to about 1 kilogram. A metal component preferably contains at least 50 percent by weight of an antimicrobial metal, further preferably contains at least 75 percent by weight of an antimicrobial metal and still further preferably contains at least 95 percent by weight of an antimicrobial metal. In another preferred embodiment, the metal component is substantially all antimicrobial metal. In particular, the metal component is capable of releasing a metal ion when an electrical current is applied to the metal component.
[0025] Materials other than an antimicrobial metal may also be included in a metal component. For instance, a metal component may further include metals which are non-antimicrobial in one configuration according to the invention, for instance to provide structural support and lower cost of the metal component. In an alternative embodiment, a non-metal constituent is included in the metal component, for instance to provide structural support and lower cost of the metal component. Exemplary non-metal constituents include such substances as inorganic and organic polymers, and biodegradable materials. A non-metal constituent or non-antimicrobial metal included in a metal component may be biocompatible. Preferably, the metal component is electrically conductive.
[0026] A metal component may be provided in any of various forms, illustratively including, a substantially pure metal, an alloy, a composite, a mixture, and a metal colloid. Thus, in one embodiment, a metal component is a substance doped with an antimicrobial metal. For instance, in a particular example, a stainless steel and/or titanium alloy including an antimicrobial metal may be included in a metal component.
[0027] By example, the antimicrobial properties of silver are particularly well-characterized and a metal component preferably contains an amount of silver, the amount in the range of 1 percent-100 percent by weight of the total composition of the metal component, although lower amounts may be included in particular embodiments. A metal component preferably contains at least 50 percent by weight of silver, further preferably contains at least 75 percent by weight silver and still further preferably contains at least 95 percent by weight silver. In another preferred embodiment, the metal component is substantially all silver.
[0028] Copper is also a preferred metal included in a metal component and a metal component preferably contains an amount of copper in the range of 1%-100% by weight of the total composition of the metal component, although lower amounts may be included in particular embodiments. In one embodiment, at least 50% by weight copper is included, further preferably a metal component contains at least 75% by weight copper and still further preferably contains at least 95% by weight copper. In another preferred embodiment, the metal component is substantially all copper. In particular, the metal component is capable of releasing a metal ion when an electrical current is applied to the metal component.
[0029] A combination of metals is also contemplated as included in a metal component. In some instances, certain metals may be more effective at inhibiting growth and/or killing particular species or types of bacteria. For example, particular metals are more effective at inhibiting growth and/or killing Gram positive bacteria, while other metals are more effective against Gram negative bacteria as exemplified in the Examples described herein.
[0030] In a particular embodiment, both silver and copper are included in a metal component. A combination of silver and copper may provide a synergistic antimicrobial effect. For instance, a lesser amount of each individual metal may be needed when a combination is used. Additionally, a shorter time during which the device is activated may be indicated where a synergistic effect is observed, allowing for conservation of a power source. The ratio of copper to silver in a metal component may range from 1000:1-1:1000. In one embodiment, a metal component preferably contains an amount of a copper/silver combination in the range of 1-100 percent by weight of the total composition of the metal component, although lower amounts may be included in particular embodiments. In one embodiment, at least 50 percent by weight of a copper/silver combination is included, further preferably a metal component contains at least 75 percent by weight of a copper/silver combination and still further preferably contains at least 95 percent by weight of a copper and silver in combination. In another preferred embodiment, the metal component is substantially all copper and silver.
[0031] In a further preferred embodiment, a metal which has antimicrobial properties but which does not have increased antimicrobial properties when an electrical current is applied to the metal is included in a metal component. For example, cadmium has antimicrobial properties effective against a wide range of microbes, as described in the Examples, and which are not increased by application of an electrical current. Such a metal is optionally included in a metal component along with one or more metals capable of releasing a metal ion when an electrical current is applied to the metal component. In particularly preferred embodiments, cadmium and silver, cadmium and copper, or cadmium, silver and copper are included in a metal component. The ratio of one or more metals capable of releasing a metal ion when an electrical current is applied to the metal component to one or more metals whose antimicrobial activity is not increased when an electrical current is applied in a metal component may range from about 1000:1-1:1000. In one embodiment, a metal component preferably contains an amount of a copper and/or silver and an amount of cadmium such that the ratio of copper and/or silver to cadmium is in the range of about 1000:1-1:1000. A combination of silver and/or copper and cadmium in a metal component is in an amount in the range of about 1-100 percent by weight of the total composition of the metal component, although lower amounts may be included in particular embodiments. In one embodiment, at least 50 percent by weight of a copper and/or silver and cadmium combination is included, further preferably a metal component contains at least 75 percent by weight of a copper and/or silver and cadmium combination and still further preferably contains at least 95 percent by weight of copper and/or silver and cadmium in combination. In another preferred embodiment, the metal component is substantially all copper and/or silver and cadmium. These and other combinations of antimicrobial metals in a metal component allow for tailoring a device to a specific situation depending on such factors as likelihood of presence of particular microbe type for example.
[0032] In a preferred embodiment, the metal component is in the form of a coating disposed on the external surface of the device. The coating can be applied by any of various methods illustratively including dunk coating, thin film deposition, vapor deposition, and electroplating. The metal component in the form of a coating ranges in thickness between 1×10 −9 -5×10 −3 meters, inclusive, preferably 1×10 −7 -4×10 −3 meters, inclusive, and more preferably between 0.5×10 −6 -5×10 −4 meters in thickness.
[0033] It is appreciated that, in the context of preferred embodiments of a device or system according to the present invention including at least two elements of a device, each element having a metal component, wherein the metal components are electrically isolated by an insulator, that each element optionally includes a metal component in the form of a metal-containing coating. In this context, the metal-containing coating on the one or more elements of the device is preferably present on at least 50 percent of the external surface of one or both elements of the device. More preferably the metal-containing coating on the one or more elements of the device is preferably present on at least 75 percent of the external surface of one or both elements of the device, and further preferably the metal-containing coating on the one or more elements of the device is preferably present on substantially all of the external surface of the one or more elements of the device. However, an insulator disposed in a current path between the metal containing coating on the surface of the one or more elements electrically insulates one element from another and thus does not include a metal-containing coating in electrical communication with a metal-containing component on the one or more elements of the device.
[0034] A coating may be disposed on a surface of a device in a patterned fashion. For example, interlocking stripes of a metal component and an insulator may be arranged on a surface of a device. Such a pattern is preferably designed to inhibit microbes in a continuous region on or near an inventive device. Thus, the distance between discontinuous regions of a coating is selected to account for the diffusion distance of ions generated from an antibacterial coating in response to an applied electrical current. Typically, ions diffuse a distance in the range of about 1-10 millimeters, but diffusion is dependent upon the medium through which the ion will travel.
[0035] A metal coating on an element of a device is preferably disposed on an external surface as a single continuous expanse of the coating material.
[0036] Optionally, the metal component is in the form of a wire, paint, ribbon, or foil disposed on the external surface of a device. Such a metal component may be attached to the device by welding, by an adhesive, or the like.
[0037] In another embodiment, the device may include an antimicrobial metal such that the device or portion thereof is the metal component. A second metal component may be further included in contact with such a device. Thus, for example, a device or portion thereof may include an alloy of stainless steel and an antimicrobial metal, and/or an alloy of titanium and an antimicrobial metal. A commercial example of such a material is stainless steel ASTM grade 30430 which includes 3% copper.
[0038] In a further embodiment, a device made of a material including an antimicrobial metal may be formulated such that the antimicrobial metal is distributed non-uniformly throughout the device. For instance, the antimicrobial metal may be localized such that a greater proportion of the antimicrobial metal is found at or near one or more surfaces of the device.
[0039] FIG. 1 illustrates a schematic circuit diagram of at least a portion of an electrical circuit included in a device according to the present invention. A first metal component disposed in electrical connection with a first element of an ex vivo device is shown at 320 and a second metal component disposed in electrical connection with a second element of an ex vivo device is shown at 322 . Each of the metal components 320 and 322 is in electrical communication with a power source 350 . As shown in FIG. 1 , the first metal component 320 is in electrical communication with a first terminal 312 of the power source 350 and the second metal component 322 is in electrical communication with a second terminal 314 of the power source 350 . Conduits 352 and 354 illustrate electrical connectors between the first and second metal components 320 and 322 and the first and second terminals 312 and 314 , respectively, of the power source. Also illustrated are an optional resistor 330 and an optional switch 340 , each in electrical communication with the power source. It is noted that the first and second metal components 320 and 322 are not in electrical contact except via the path 352 - 350 - 354 . In use, an antimicrobial device according to embodiments of the present invention has first and second metal components 320 and 322 connected via an electrical conductor. In particular embodiments, an electrical conductor is not an integral part of an inventive device, the electrical conductor is a microbe, the hand of a user, environmental humidity or other such conductor.
[0040] In an alternative embodiment, one element, either 320 or 322 , has a potential charge relative to the other element. When one of the elements, either 320 or 322 is brought into contact with an object that is relatively neutral or opposite in charge with respect to the non-contacted element, the charge is dissipated into the object, providing an antimicrobial effect.
[0041] An antimicrobial device may be any of various devices which may be broadly described as having a surface likely to harbor undesirable microbes which may then be transferred to an individual who comes in contact with the surface, directly or indirectly. Such devices include clothing; bed linens, towels, filter masks intended to be worn by a human; medical equipment, such as a stethoscope, an endoscope or probe; handheld devices, such as a remote control for an electronic device, a PDA, a headset, an earpiece, a portable or non-portable telephone and a pager; processing equipment for consumables such as foods and drugs, such as a meat grinder, a mixer, a food container, and a utensil; ventilation systems and parts therefore, such as an air handler or an air filter; and dispensers of various types, illustratively including a tissue dispenser and a paper towel dispenser. Further embodiments include surfaces such as a food preparation surface in a kitchen, an examination table used by a physician or veterinarian, a laboratory bench, a bathroom surface such as a sink, toilet, bathtub or shower surface, a bathroom accessory, such as a shower or bathmat, a drain cover, and a toilet brush. Additional embodiments include personal care accessories, illustratively including a toothbrush, and a hairbrush or comb. Hardware devices are provided according to the present invention, illustratively including a doorknob or door handle, a hand railing, a drinking fountain actuator, bathroom hardware and a vehicle steering wheel.
[0042] FIG. 2 illustrates an embodiment of an antimicrobial doorknob device 200 according to the present invention. An embodiment of an inventive antimicrobial doorknob includes at least two portions, a first element 202 and a second element 204 , each element having an external surface. A first antimicrobial metal component 203 is illustrated disposed on the external surface of the first element 202 . A second antimicrobial metal component 205 is illustrated disposed on the external surface of the second element 204 .
[0043] An internal power source is included in the illustrated embodiment, in the form of an electrochemical cell, at 208 . The power source 208 is disposed in an internal cavity 207 formed in the second element 204 . One terminal of the power source is in electrical communication with the first element 202 and the first antimicrobial metal component 203 . The second terminal of the power source is in electrical communication with the second element 204 and the second antimicrobial metal component 205 .
[0044] An insulator 206 is shown which prevents current flow from the first element 202 and/or first antimicrobial metal component 203 to the second element 204 and/or second antimicrobial metal component 205 without completing a circuit through the first antimicrobial metal component 203 , the second antimicrobial metal component and an electrical conductor in contact with the surface of the device (not shown). It is noted that resistive value of the insulator 206 is greater than the resistive value of the hand or other such electrical conductor that completes the circuit 203 to 205 when touching the doorknob.
[0045] An electrical conductor in contact with the surface of the device which completes the electrical circuit may be any suitable electrical conductor. The completion of the circuit allows for current-induced release of antimicrobial metal ions from the one or more antimicrobial metal components.
[0046] In one embodiment, an electrical conductor comes into contact with an inventive device during normal use. For example, in the context of an antimicrobial doorknob, a human hand may serve as an electrical conductor which completes the circuit. Released antimicrobial ions inhibit growth of microbes transferred from a human hand to a doorknob in regular use and also inhibit transfer of microbes from the doorknob to a hand.
[0047] In a further example, a food preparation surface comes into contact with an electrical conductor in the form of a food or moisture in the course of regular use of the food preparation surface. Thus, in an embodiment of the present invention in the form of a food preparation surface is configured such that a food completes the circuit during use of the surface.
[0048] In another embodiment, an electrical conductor may be applied to complete the circuit at a desired time. For example, an electrical conductor may be applied at the end of a work period and prior to the beginning of the next work period. In an illustrative example, such an electrical conductor is optionally a conductive blanket used to cover a work surface such as a work table or counter at the end of a work day or during periods of non-use.
[0049] A device according to an embodiment of the present invention includes first and second elements protruding from a base, such as a toothbrush, bathmat, hairbrush, and comb. FIG. 5 illustrates a cross-section of a portion of one such embodiment 400 showing protrusions 402 extending from a base 403 . A first antimicrobial metal component 406 is illustrated disposed on the external surface of the first element 404 . A second antimicrobial metal component 407 is illustrated disposed on the external surface of the second element 405 .
[0050] A power source (not shown) is connected to the device 400 such that one terminal of the power source is in electrical communication with the first element 404 and the first antimicrobial metal component 406 . The second terminal of the power source is in electrical communication with the second element 405 and the second antimicrobial metal component 407 . For example, the terminals may be connected by wires such as shown at 409 and 410 .
[0051] An insulator 408 is shown which prevents current flow from the first element 404 and/or first antimicrobial metal component 406 to the second element 405 and/or second antimicrobial metal component 407 without completing a circuit through the first antimicrobial metal component, the second antimicrobial metal component and an electrical conductor in contact with the surface of the device (not shown). In the embodiment shown in FIG. 5 , an insulator is an air space 408 . Additionally, the base 403 is configured so as to prevent flow of current from 404 / 406 to 405 / 407 without completing a circuit through the first antimicrobial metal component, the second antimicrobial metal component and an electrical conductor in contact with the surface of the device. An electrical conductor completing the circuit is illustratively a liquid or gel used in tooth cleaning, such as saliva, toothpaste and/or water, a body part contacting the device, such as a human hand, foot and/or scalp.
[0052] FIG. 6 illustrates a cross-section of a portion of a further embodiment of a device 500 according to an embodiment of the present invention including multiple protrusions 502 extending from a base 503 . The protrusions 502 shown include a first antimicrobial metal component 506 is illustrated disposed on the external surface of the first element 504 . A second antimicrobial metal component 507 is illustrated disposed on the external surface of the second element 505 .
[0053] A power source (not shown) is connected to the device 500 such that one terminal of the power source is in electrical communication with the first element 504 and the first antimicrobial metal component 506 . The second terminal of the power source is in electrical communication with the second element 505 and the second antimicrobial metal component 507 . For example, the terminals may be connected by wires such as shown at 509 and 510 .
[0054] An insulator 508 is shown which prevents current flow from the first element 504 and/or first antimicrobial metal component 506 to the second element 505 and/or second antimicrobial metal component 507 without completing a circuit through the first antimicrobial metal component, the second antimicrobial metal component and an electrical conductor in contact with the surface of the device (not shown). In an embodiment shown in FIG. 6 , a further insulator is an air space 512 . Additionally, the base 503 is configured so as to prevent flow of current from 504 / 506 to 505 / 507 without completing a circuit through the first antimicrobial metal component, the second antimicrobial metal component and an electrical conductor in contact with the surface of the device. An electrical conductor completing the circuit is illustratively a liquid or gel used in tooth cleaning, such as saliva, toothpaste and/or water, a body part contacting the device, such as a human hand, foot and/or scalp.
[0055] FIG. 7 illustrates an embodiment of an inventive device 600 . A device 600 provides a surface which can be incorporated in various devices for antimicrobial effect illustratively including fabric-based article such as an article of clothing, a towel, and/or bed linens such as sheets and blankets; a filter mask; an item of medical equipment; a handheld electronic device; an item of processing equipment for a consumable; a ventilation system component; a wipe dispenser; a food preparation surface; an examination table for a human or an animal; a laboratory bench; a bathroom surface; a bathroom accessory; a personal care accessory; and a hardware apparatus. An inventive device 600 includes a plurality of antimicrobial metal components disposed on the external surface of a plurality of first elements 602 , and a plurality of second elements 604 , labeled “grounding material.” Optionally, a plurality of second antimicrobial metal components is disposed on the external surface of at least one of the plurality of second elements.
[0056] Each of the individual first and second elements are separated by an insulator 606 . The size of the insulator and thus the size of the separation between an individual first element and an individual second element is selected to optimize an antimicrobial effect. In general, an insulator is dimensioned such that an individual first element and an individual second element are separated by about 0.1 micron-10 cm, inclusive, although not limited to this range of sizes.
[0057] A power source 608 is connected to the device 600 such that one terminal of the power source is in electrical communication with the plurality of first elements and the plurality of first antimicrobial metal components. The second terminal of the power source is in electrical communication with the plurality of second elements.
[0058] In a further embodiment, an antimicrobial device is provided which includes a device body having a first element having a first external surface and a second element having a second external surface, a first metal component containing an antimicrobial metal disposed on the first external surface of the device body, a power source having a first terminal and a second terminal, the first terminal in electrical communication with the first metal component; and an insulator placed in a current path between the first terminal of the power source and the second terminal of the power source preventing current flowing from the first terminal from reaching the second terminal, wherein activation of the power source creates a potential between the first element and the second element such that placement of an object in contact with the antimicrobial metal results in movement of metal ions from the antimicrobial metal toward the object.
[0059] An exemplary embodiment of such an inventive device 700 is shown in FIG. 8 . An antimicrobial device 700 includes an antimicrobial metal component disposed on the external surface 702 of a first element 704 . As described above, a first element and/or second element is optionally fabricated partially or wholly from an antimicrobial metal. A second element, 706 , labeled “grounding material,” is depicted and the first and second elements, 704 and 706 , respectively, are separated by an insulator 708 , labeled “insulating material” in FIG. 8 . The size of the insulator and thus the size of the separation between the first element and the second element is selected to optimize an antimicrobial effect. In general, an insulator is dimensioned such that an individual first element and an individual second element are separated by about 0.1 micron-10 cm, inclusive, although not limited to this range of sizes.
[0060] A power source 710 is connected to the device 700 such that one terminal of the power source is in electrical communication with the first element and the first antimicrobial metal component. The second terminal of the power source is in electrical communication with the second element.
[0061] A device according to the present invention is optionally directly grounded or may use a “floating” ground.
[0062] In an embodiment such as shown in FIG. 8 , a potential is created between the antimicrobial metal 702 and the second element 706 . When an object, not shown, which is neutral or negatively charged with respect to the surface 702 is placed in contact with the surface 702 , metal ions from the antimicrobial metal move towards the object, providing an antimicrobial effect. It is noted that a circuit is not completed by the object in an embodiment as illustrated in FIG. 8 . The object is illustratively an object typically used in conjunction with the device or which otherwise comes in contact with the device. For example, where the device 700 is incorporated in a food preparation surface, the object is illustratively a food item, a utensil, a user's hand and/or a microbe. A device 700 is optionally incorporated in antimicrobial devices of various types, illustratively including a fabric-based article such as an article of clothing, bed linens, and/or a towel; a filter mask; an item of medical equipment; a handheld electronic device; an item of processing equipment for a consumable; a ventilation system component; a wipe dispenser; a food preparation surface; an examination table for a human or an animal; a laboratory bench; a bathroom surface; a bathroom accessory; a personal care accessory; and/or a hardware apparatus.
[0063] FIG. 9 illustrates an embodiment including a first component including an antimicrobial metal in the form of a “coating material,” a second component labeled “base material” and an insulator labeled “insulating layer” disposed between the coating material and base material. FIG. 9 graphically illustrates silver ions moving towards bacteria in contact with the first component, the silver ions providing an antimicrobial effect on the bacteria.
[0064] Embodiments of inventive compositions and methods are illustrated in the following examples. These examples are provided for illustrative purposes and are not considered limitations on the scope of inventive compositions and methods.
Example 1
[0065] Procedures to identify an antimicrobial metal composition for use in an included metal component may include an examination of each metal's antimicrobial potential using a panel of common Gram (+) and Gram (−) bacterial, fungal species or other microbes. a method adapted from the Kirby Bauer agar gel diffusion technique, the antimicrobial efficacy of eight metals: silver, copper, titanium, gold, cadmium, nickel, zinc and stainless steel AISI 316L and their electrically generated ionic forms are tested against 5 bacterial species and one fungus.
[0066] Strains of Esherichia coli, S. aureus, Pseudomonas aeruginosa, Enterococcus faecalis , Methicillin resistant S. aureus (MRSA), and Candida albicans isolated from samples submitted to the Pennsylvania State University Animal Diagnostic Laboratory ( E. coli, S. aureus, P. aeruginosa and E. faecalis ) or J.C. Blair Hospital, Huntingdon, Pa. (MRSA and C. albicans ), are diluted to a 0.5 MacFarland standard and inoculated onto Mueller-Hinton agar plates (Remel, Lenexa, Kans.).
[0067] Metallic wires served as the ion source, specifically: silver (99.97% purity), copper (99.95+% purity), titanium (99.8% purity), gold (99.99% purity), cadmium (99.999% purity), nickel (99.98% purity), zinc (99.999% purity) and stainless steel AISI 316L. All wires are of uniform equal diameter (1.0 mm).
[0068] Small holes are burned into opposite sides of the Petri plates which allowed for the aseptic threading of 32 mm lengths of test wire into the agar. Once embedded, 1 cm2 of wire surface area is exposed to the growing microbes.
[0069] Electrical currents are generated by placing a standard 1.55 Volt AA battery in series with one of the following resistors: 3.01 MΩ, 1.5 MΩ, 150 kΩ and 75 kΩ. A 70 mm length of each of the test metals is connected in series with the given resistor. The current that is generated by each of the four different resistors (3.01 MΩ, 1.5 MΩ, 150 kΩ and 75 kΩ) is 0.5 μA, 1.0 μA, 10 μA, and 20 μA respectively. The 20 μA/cm2 surface area charge is proven in 1974 to be a safe electrical exposure value for the cells. (Barrnco 1974) As calculated with Faraday's equation, a 20 μA/cm 2 surface area charge density produced over 80 μg/hour of silver ions.
[0070] The circuit is completed by aseptically threading the anode through the opposite hole and embedding it into the agar. One control plate for each microbial species is aseptically threaded with wires, but received no electrical current. The plates are incubated in ambient air at 37° C. for 24 hours, and subsequently examined for bacterial growth and/or zones of inhibition.
[0071] Of the eight metals and metal ions tested, silver ions and cadmium show bactericidal efficacy against all bacterial species tested, and copper ions showed bactericidal efficacy against Gram-positive bacteria. Titanium, gold, nickel, zinc and stainless steel AISI had no significant effects in this example.
[0072] Exemplary results are shown in Table 1 in which numbers represent measurements of the diameter of the zone of inhibition in millimeters around the central wire. The table shows that silver has some microbiocidal properties when not electrically ionized, since E. coli is inhibited by non-charged silver. A smaller current produced results similar to larger currents, and in all cases the addition of current increased the size of the inhibition zone.
[0073] Copper also shows antimicrobial properties, both in the ionic form and the uncharged metallic form, as summarized in Table 1. In the uncharged form copper showed bactericidal properties against E. faecalis . A minimal current produced bactericidal results for all Gram (+) species of bacteria, and higher currents produced larger zones. Copper did not have an effect on Gram (−) bacterial species at currents used.
[0074] Surprisingly, cadmium results are unique in producing antimicrobial effects against all organisms tested, and the pattern of efficiency held true both in the absence and presence of electrical stimulation. Increasing the current resulted in minimal changes in microbial response. Cadmium produced a double zone of inhibition: an inner zone of complete clearing closer to the wire, and an outer zone of decreased bacterial growth (incomplete clearing). For descriptive purposes, the inner zone is considered to be “microbiocidal”, while the outer zone is considered “microbistatic”, or inhibitory. Numbers shown in Table 1 reflect this double zone of inhibition such that the size of the “inner zone” is present first and the size of the “outer zone” is presented in parentheses. Additionally, cadmium consistently showed some inhibitory effect in the absence of electrical charge; increasing the current had little additional effect.
[0000]
TABLE 1
Gram Positive
Gram Negative
Fungus
S.
E.
P.
C.
Current
aureus
faecalis
MRSA
E. coli
aeruginosa
albicans
Silver
0 μA
6
0
0
5
0
0
0.5 μA
18
17
18
20
18
34
1 μA
20
19
18
21
21
30
10 μA
20
21
18
25
21
32
20 μA
20
20
18
24
20
30
Gold
0 μA
3
0
0
0
0
0
0.5 μA
0
0
0
0
0
0
1 μA
0
0
0
10
0
0
10 μA
0
0
0
0
0
0
20 μA
0
0
0
0
0
0
Titanium
0 μA
0
0
0
0
0
0
0.5 μA
0
0
0
0
0
0
1 μA
0
0
0
0
0
0
10 μA
0
0
0
0
0
0
20 μA
0
0
0
0
0
0
Copper
0 μA
0
11
0
0
0
0
0.5 μA
14
16
7
0
0
0
1 μA
6
16
6
0
0
0
10 μA
0
15
9
0
0
0
20 μA
8
18
11
0
0
0
Stainless steel
0 μA
0
0
0
0
0
0
0.5 μA
0
0
0
0
0
0
1 μA
0
0
0
0
0
0
10 μA
0
0
0
0
0
0
20 μA
0
0
0
0
0
0
Cadmium
0 μA
8 (15)
5
14
6 (18)
(17)
28
0.5 μA
6 (10)
6
13
5 (18)
(12)
28
1 μA
8 (15)
6
13
4 (18)
(18)
31
10 μA
6 (14)
5
15
6 (18)
(16)
30
20 μA
7 (15)
5
16
5 (17)
(18)
30
Zinc
0 μA
0
0
0
0
0
0
0.5 μA
0
0
0
0
0
0
1 μA
0
0
0
0
0
0
10 μA
0
0
0
0
0
0
20 μA
0
0
0
0
0
0
Nickel
0 μA
0
0
0
0
0
0
0.5 μA
0
0
0
0
0
0
1 μA
0
0
0
0
0
0
10 μA
0
0
0
0
0
0
20 μA
0
0
0
0
0
0
Example 2
Characterization of Effective Antimicrobial Metals
[0075] A “killing curve analysis” may be performed in order to characterize parameters which achieve an antimicrobial effect. A predetermined number of colony forming units/ml (CFU/ml), established in a growth medium, are transferred to a saline solution and then exposed to the antimicrobial metal or metal form. At predetermined time intervals, an aliquot is removed, diluted (if necessary), inoculated onto blood agar plates and incubated overnight at 37° C. The resulting growth is quantified as CFU/ml. A graph, with time as the X-axis and CFU/ml as the Y-axis demonstrates the point at which the antimicrobial effect and microbial population growth intersect. The concentration of metal required for antimicrobial effect can be determined by examining the time point at which the microbial population begins to decrease.
[0076] To examine the rate of diffusion of ions away from the metal source, i.e. the rate at which the microbes are inhibited from growing (or killed), high performance microscopy may be used. A high performance microscopic system developed by Cytoviva allows for real-time observation of living cells and cellular components without the use of staining agents. By observing the microbial response to a given metal, a “velocity” of microbial destruction can be directly observed. The rate of diffusion of ions through agar can be inferred from the velocity of kill.
[0077] In this example, silver is tested with respect to two different bacterial species, E. coli and S. aureus . A current of 0.5 μA is used in this example.
[0078] Strains of E. coli and S. aureus isolated from samples submitted to the Pennsylvania State University Animal Diagnostic Laboratory, are separately diluted to a 0.5 MacFarland standard and added to individual test tubes containing 10 mls of sterile Tryptic Soy Broth (TSB). A silver wire (99.97% purity) having a uniform diameter of 1.0 mm served as a source of ions.
[0079] Two small holes are burned into the screw cap of each test tube. Silver Wires (99.97% purity), having uniform diameters of 1.0 mm, served as ion sources. The wires are aseptically threaded through the screw cap holes and positioned to expose a total length of 32 mm into the previously inoculated TSB. This resulted in the exposure of 1 cm 2 of silver wire to growing bacterial cells. Electrical current is generated by placing a standard 1.55 Volt AA battery in series with a 3.01 Mil resistor. The current that is generated by the 3.01 MO resistor is 0.5 μA when combined into the circuit. Additionally a circuit, formed without any resistor is utilized and inserted into a tube in an identical fashion. The circuits are completed by aseptically threading the anode through another hole in the test tube screw cap and into the TSB. One tube of each bacterial species, serves as the control. It contained a silver wire, but no external circuit is connected. The silver wire as well as the anode wire is placed in contact with the bacterially laden broth continued within the test tube. This setup is used to produce “killing curves”.
[0080] The tubes are incubated in air at room temperature for a total of 8 hours. Every hour the test tube is vortexed for approximately 10 seconds. The test tube cap is then opened and a 10 μl sample of broth is aseptically drawn from the test tube. The test tube are again closed and vortexed. The sample is plated onto blood agar plates using a spiral plating technique. The blood agar plates are incubated at room temperature for 24 hours. The number of colonies present on the blood agar plates at 24 hours are counted and recorded.
[0081] The results clearly demonstrate that the charged form of the silver metal has a much greater kill rate when compared to the non-charged material. A “killing curve” shown in FIG. 3 shows the killing rate associated with S. aureus . The results clearly demonstrate a bacterial reduction rate of approximately 5.698*10E12 bacteria per hour. Within this time frame both the control and the silver with no resistor allow bacterial growth.
[0082] A “killing curve” for Escherichia coli in FIG. 4 shows the killing rate associated with E. coli . The 3MΩ resistor utilized in this circuit corresponds to the smallest current 0.5 μA. The curve shows bacterial reduction from 320*10E6 to zero within five hours, a rate of approximately 72*10E6 bacteria per hour. Within this time period both the control and the silver with no resistor tests continue to support bacterial growth.
Example 3
Optimization of Critical Operational Parameters of Antimicrobial Metals
[0083] Antimicrobial properties of specific metals or metal forms differ when modifications are made in the experimental parameters. Using data from the “killing curve analyses”, critical parameters will be established for the generation of optimal antimicrobial effects, and can then be balanced against the characteristics of the application into which the metal will be incorporated.
[0084] In order to evaluate any possible toxicity of antimicrobial metal compositions on mammalian cells, in vitro cell culture systems may be utilized. Specifically, batteries and resistors connected in series with a predetermined antimicrobial metal composition is aseptically threaded into a mammalian cell culture flask and allowed to run, generating metal ions within the culture. Cells are monitored during testing for morphological changes and percentages of live vs. dead cells. In addition, treated and control cells may be evaluated via metabolic function assays such as albumin and urea levels in hepatocytes; bone alkaline phosphatase levels in osteoblasts; and matrix protein levels in chrondrocytes.
[0085] In addition, the effects of circuit polarity, operation time and duty cycle are evaluated on cells in vitro using device parameters and optimized for maximal antimicrobial effect and low toxicity. An external circuit is constructed allowing for varying run-time cycles and alternating circuit polarities. The external circuit with battery, resistor, an inverter for reversing polarity, and a timer will be connected in series with the test antimicrobial metal. The circuit will be aseptically threaded into the cell culture flask and allowed to run, generating antimicrobial ions within the culture. The continuous running time of the circuit as well as the polarity of the circuit will be manipulated by varying the circuit timer and changing the polarity of the circuit via the switch.
[0086] Any patents or publications mentioned in this specification are incorporated herein by reference to the same extent as if each individual publication is specifically and individually indicated to be incorporated by reference.
[0087] The compositions and methods described herein are presently representative of preferred embodiments, exemplary, and not intended as limitations on the scope of the invention. Changes therein and other uses will occur to those skilled in the art. Such changes and other uses can be made without departing from the scope of the invention as set forth in the claims.
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A method and device for destroying and inhibiting exposure to microbes and infection includes a first element and a second element, and a power source. At least one of the elements includes antimicrobial metal, which, when energized by the power source, produces ions that are lethal to microbes. The device can be incorporated into virtually any useful object. During normal use of the object, electrical communication is established between the two elements, causing current supplied from the power source to flow through the antimicrobial metal. The two elements are configured and arranged to ensure that ions flowing from the antimicrobial metal flow through the region in which it is desired to kill microbes. The antimicrobial metal can be on the surface of the element, incorporated into the material making up the element, or provided in any other way that allows the antimicrobial effect to be achieved.
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SUMMARY OF THE INVENTION
The invention is a solar energy collector having a weightless balloon comprising, in combination, a base; a spherical, reinforced plastic balloon having a substantially transparent hemisphere and an internally reflective hemisphere, the balloon being inflated with a lighter-than-air gas making it substantially weightless. A multi-tube boiler probe is hermetically secured in an opening in the balloon, the opening being substantially centrally located in the reflective hemisphere. A portion of the probe is outside the balloon and a portion of the probe extends into the balloon at the focus of sunlight reflected from the reflective hemisphere. Means are provided for conducting coolant to and from the probe, the coolant entering and exiting the portion of the probe outside the balloon and circulating within the tubes of the probe through the portion of the probe in the balloon and the coolant being heated within the probe by direct and reflected sunlight striking the probe. Means are also provided for securing the balloon and probe to the base, the securing means including means for tilting and rotating the balloon relative to the base to maintain the balloon in a predetermined orientation with the sun for optimum transmission of sunlight through the transparent hemisphere to the reflective hemisphere.
The transparent hemisphere of the balloon of the collector is a clear, weather- and ultra-violet light-resistant polyvinylfluoride film reinforced with a mesh of ropes adhesively secured to the outside surface of the transparent hemisphere. The reflective hemisphere is a laminate of two plastic films, the inner film being clear and ultra-violet light resistant and its outside surface being aluminized; the outer film being white, opaque and weather-resistant. The outside surface of the reflective hemisphere is reinforced with a fine mesh-woven cloth adhesively secured to the outside surface.
The collector probe comprises three concentric tubes, the inner tube defining a conduit for coolant fluid heated by the sun, the annular space between the outer and intermediate tubes being in fluid-flow communication with the inner tube and providing a conduit for coolant fluid to be heated, and the annular space between the inner and intermediate tubes being sealed and evaculated to provide vacuum insulation against convective heat transfer between heated coolant fluid in the inner tube and coolant fluid in the outer tube.
The balloon of the collector has a diameter up to 800 feet.
The balloon of the collector is inflated with a lighter-than-air consisting of a mixture of 92 to 95% nitrogen and 8 to 5% hydrogen to a pressure approximately equal to five inches of water.
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate one embodiment of the invention and, together with the description, serve to explain the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWING
The single FIGURE is a cross-sectional side view of the collector of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In accordance with the claimed invention, the collector comprises a base, a spherical, reinforced plastic balloon, a multi-tubed probe, means for conducting coolant fluid to and from the probe, and means for securing the balloon and probe to the base including means for tilting and rotating the balloon relative to the base. Each of these basic components of the collector will now be discussed in detail.
Balloon Type Collector-Reflector
A weather resistant reinforced plastic balloon 12 would be used. The balloon 20 would be spherical, have two hemispheres 16 and 18 and balloon equator 20 would be at right angles to the axis of a probe 14. Upper hemisphere 16 nearest to sun would be of four-mil thick, polished, water clear, weather resistant, ultra violet light resistant, polyvinyl-fluoride (Tedlar) film or equal. Upper hemisphere 16 skin would be reinforced by a mesh of Kevlar yarns or equal woven into ropes 22 and adhered to skin using weather resistant, ultra violet light resistant adhesive. Ropes 22 would be on 12 to 18-inch centers and designed to resist 100 mile-per-hour wind forces. Solar light rays would enter balloon 12 through clear skin with rays parallel to probe axis. Incoming light transmission would be close to 85% with 14% loss due to reflection from surfaces of clear skin and 1% loss due to blockage by rope 22 mesh reinforcement.
Lower hemisphere 18 away from sun would be a 4-mil thick laminate consisting of two plastic films. Inner film 24 would be of two-mil thick, water clear, ultra violet light resistant Mylar or equal with heavily aluminized outer surface away from sun. Outer film 26 would be of 2-mil thick, opaque white, weather resistant Tedlar or equal. These two films would be press-rolled against a relatively fine mesh cloth (not shown) woven of 1000 Denier Kevlar yarns pretreated with ultra violet light resistant adhesive and designed to resist 100 mile-per-hour wind forces. Incoming light rays would pass through Mylar film and be reflected into probe 14. Aluminized surface of Mylar inner film 24 backed by opaque white Tedlar would block and reflect essentially all incoming light toward probe 14 except 4% which would be reflected from inner Mylar surface but which will also be directed into probe 14.
All balloon skin panels will be close to 6.28 feet wide and seams will be concentric circles parallel to equator to reduce skin material wastage and balloon skin assembly labor to an absolute minimum. Seams 20 would be butt-type using 2-inch wide tapes inside and out of 2-mil thick, clear Tedlar tape reinforced with Kevlar yarn cloth and pretreated with weather and ultra violet light resistant, pressure-sensitive adhesive or equal. Balloon 12 would be inflated with probe 14 temporarily in a vertical direction using nitrogen separated from ambient air using a cryogenic separator. Balloon 12 fill pressure would be 5 inches of water to prevent surface billowing when wind stagnation point velocity is 100 miles per hour. About 5% of the nitrogen would be withdrawn and replaced with hydrogen to make balloon and its tether cables weightless. The resulting 95-5 nitrogen-hydrogen gas mixture in balloon would have a density of close to 0.068 pounds per cubic foot and is not flammable. Once balloon is properly filled it can be aimed away from vertical without imposing an overturning moment against its own foundation. Balloon 12 of large diameter would require a top-mounted lightning rod 28 and grounding lead 30, separated from the balloon 12 by dielectric standoffs 32, plus small aircraft warning lights.
Rope Tethers Against Wind Forces
Kevlar yarns or equal used to make rope 34 would be 1000 Denier and each yarn would be of 666 Aramid fibers and have a design breaking pull of 60 pounds. Yarns used to make reinforcement meshes would have a design pull of 42 pounds each and are held in place against balloon skin as described above. Yarns used to make rope fingers and rope tether cables would be de-rated 50% to a design pull of 21 pounds each to allow for wear and tear and continuous flexing as wind forces vary. Probe 14 would extend into balloon 12 for a distance equal to 7/16 of balloon radius. Probe 14 would extend outside of balloon 12 to a rope tether cable anchoring ring 36 located at a distance of close to balloon diameter divided by the square root of three from balloon center.
Tether vang pads at balloon surface would be located on a tethering diameter 38 of one-half of balloon diameter. Kevlar rope fingers attached to balloon skin at 15-inch centers would converge in groups of five to join balloon end of Kevlar rope tethering cables 34 at a distance of 6.28 feet from balloon 12 surface. Tether rope cables 34 would be at close to 6.28 feet on centers at balloon ends and any half of them would be designed to resist 100 mile-per-hour wind forces in tension based on a drag factor of 0.4 and a lift factor of 0.2. Wind forces would be transferred to a tether anchoring ring 36 mounted on probe 14 and transverse to probe axis. Overall length of a tether rope cable 34 and its fingers would be close to balloon radius divided by the square root of three. When deployed, tether cables 34 will be at an angle of 60° with respect to axis of probe 14. Tether connectors at tether ring 36 will be adjustable to permit accurate deployment of balloon. Tether ring 36 will be braced stiffly to probe barrel using cones of thin-walled carbon steel plate.
Multi-tubed Probe for Converting Solar Light to Heat
Probe 14 would consist of three tubes 38, 40, 42 manufactured to boiler tube dimensions which will allow a wide selection of sizes. Nominal thickness of tubes will be 1/8 inch and construction will be all-welded except occasional ceramic wedges would be used to center tubing and transmit structural loading as to allow probe to resist bending as a unit. Inner tube 42 would be a flow passage for coolant removing heat from the probe 14. The annular space between the inner tube 42 and intermediate tube 40 would be evacuated to a hard vacuum pressure low enough to eliminate convective heat transfer between these two tubes. The occasional ceramic wedges 43 will block conductive heat transfer except at outer end 44 of probe 14 nearest sun where there is no temperature difference. The annular space between the intermediate tube 40 and the outer tube 38 would be a flow passage for coolant arriving to pick up heat from the outer tube 38 where conversion of solar light to thermal heat will take place. A small amount of heat will be lost from the inner tube 42 to the intermediate tube 40 in the vicinity of probe entry through balloon surface. All such losses will be picked up by arriving coolant and recycled. At very high collection temperatures this effect would be minimized by adding from 10 to 30 wraps of superinsulation with aluminized Mylar bright side aimed at hotter intermediate tube.
Outer tube 38 for large collectors would have its exterior surface treated to preferentially absorb solar light and allow a maximum conversion to heat captured in tube metal while minimizing re-emission heat losses below those of a perfect black body. This generally has been done by coating a metal with a thin layer of metal-oxide 48 and improvements by a factor of ten can be expected. With respect to this invention no claim is made as to selective surfaces except that best commercially available techniques would be used. It is not precluded that at very high collection temperatures novel techniques may be desirable or even necessary to prevent excessive losses due to re-emission but this Petition does not attempt to describe such future techniques.
Portion of probe outside of balloon will be provided with insulation 46 to minimize heat losses to ambient and prevent overheating of balloon skin or tether cables. At very high temperatures some of this insulation 46 would have to be ceramic. In such cases a bright metal collar 50 curved to balloon surface shape would be affixed to probe 14 using soft metal seals and have attached back side finning to dissipate heat and temperature to point where affixment of balloon reflective skin can be effected using means that are reasonable at close to ambient temperature. A balloon fill valve 51 is provided in the collar 50 to provide means for inflating the balloon 12. Probe tubing would be weather-resistant carbon steel to 800° R., low carbon austenitic stainless steel to 1600° R., 5% iron content superalloy to 2,400° R., rhodium clad molybdenum to 3,200° R. and tantalum clad sintered tungsten at higher temperatures. At very high collection temperatures probes 14 may tend to go limp and trussings of stainless wire pulled tight over ceramic or finned stainless steel stand-offs could be used to insure probe 14 stability. Probe coolant can be any fluid suited to the intended service. At higher temperatures sodium-potassium alloy (NAK) at close to its eutectic point could be used. This would preclude freeze-ups in normal night climates and would allow very high temperature heat pickup without mandating high pressures which in turn could require very a thick-walled probe. A thick-walled probe would be inappropriate for both structural design and cost considerations.
The probe 14 also has an inlet port 47 in fluid-flow communication with the annular space between the outer tube 38 and the intermediate tube 40 and an outlet port 51 in fluid-flow communication with the interior of the inner tube 42 providing means for coolant fluid flow into and out of the probe 14. The probe also includes a vacuum port 49 in fluid-flow communication with the annular space between the intermediate tube 40 and the inner tube 42 for evacuating the annular space.
Tracking Mount to Support Probe and Continuously Aim it at Sun
Such Mounts exist and have been used to support solid radar dishes of modest dimensions or larger radar dishes of more open design. Swivel-shaft 52 diameter must resist full wind forces in shear. Swivel shaft 52 location must allow raising of probe 14 to zenith to facilitate inflation of balloon 14 and also permit its location and use at the equator of our planet. Swivel shaft bearing journal bracing 54 must transmit wind force from tether anchoring ring 36 to horizontal mount support ring or vertical shaft 56 without undue deflection or quiver amplitudes. A probe support collar 57 is secured on the end of the swivel shaft 52 for attaching the probe 14 to the swivel shaft 55. Probe tilt would be accomplished using a hyraulic cylinder 58 with positioneer capable of being manually set and operated automatically. Pistons would be provided with mechanical stops and alarm actuating contacts to prevent disastrous tiltings. Horizontal mount drives 60 would be reversing, geared clock motors. Geared track would be provided with mechanical stops to prevent winding up coolant flexible hose 62 connections as well as automatic alarms and manual overrides. Horizontal track would be caged to prevent overturn and transmit wind forces to a reinforced concrete base 10. Mount arrangement would be as close to grade as practical to minimize wind force moment arms. Tracking mounts would be fabricated of weather resistant carbon steel and cast iron parts or better to insure long, trouble-free operation in all varieties of climate.
Concrete Base to Anchor Balloon Against Wind Forces and Support the Tracking Mount
Slab thickness of concrete base 10 would be a minimum of three feet to allow it to be economically reinfoced to act as a beam in any direction. For collectors of very large diameter a truncated cone of reinforced concrete would be located at the middle of the concrete base to transmit large wind forces into the ground 65 in a reasonable manner while minimizing requirements for tracking mount carbon steel weldments. Concrete base 10 diameter and its reinforcement would be designed to bring resultant force into the ground 65 within a circle having a diameter of concrete base diameter divided by three to prevent excessive soil pressures at concrete base rim. Where local ground conditions are particularly poor or unstable, rings of sheeting or piles would be provided.
Source of Low Voltage 60 Hz Electrical Power to Energize Tracking Mount Drive Motors
Such a power source is readily available from local utility company distribution lines, the housepower bus of a solar energy thermal electric plant, a small fuel cell or battery-powered invertor unit or a small gas-fired engine generator set.
Instrumentation & Controls to Permit Parallel Operation of Groups of Collectors
Present materials tend to limit balloon diameters to 800 ft. or less. At a collection temperature of 2,400° R. to 3,200° R. such a collector could collect close to 36 MWt when sun is shining. This heat source could power thermal cycle or cycles generating from 15 MWe to 22 MWe using the best modern equipment. Sunlight at best is available about one-third of time. Thus a solar plant of size would require a number of 800-foot diameter collectors. Such farms of solar energy collectors would be provided with instrumentation and controls to permit parallel operation. Based on recent development of solid-state mini-computers this requirement would have a minimal overall plant cost impact.
Thermally Insulated Flexible Metal Coolant Hose Connections Between Probe and Extraneous Recirculated Coolant Piping System Supply and Return Mains
Such hose 62 connections would be provided to supply cool coolant to probe 14 and receive hot coolant from probe 14 in order to make the transition between the tracking mount which constantly moves either east to west or west to east and the stationary coolant supply-and-return mains. All components of the extraneous coolant system are commercially available or would be simple extrapolations to higher service temperature operation. At very high service temperatures heat would be transferred to thermal power cycle vapor or condensate using very compact platefin-type heat exchangers which would result in low cost heat exchange as compared to fossil-fuel fired boilers which inherently require large banks of thick-walled tubing to receive heat from flue gas at very low overall U factors.
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A solar energy collector having a weightless balloon, the balloon including a transparent polyvinylfluoride hemisphere reinforced with a mesh of ropes secured to its outside surface, and a laminated reflector hemisphere, the inner layer being clear and aluminized on its outside surface and the outer layer being opaque, the balloon being inflated with lighter-than-air gas. A heat collection probe extends into the balloon along the focus of reflection of the reflective hemisphere for conducting coolant into and out of the balloon. The probe is mounted on apparatus for keeping the probe aligned with the sun's path, the apparatus being founded in the earth for withstanding wind pressure on the balloon. The balloon is lashed to the probe by ropes adhered to the outer surface of the balloon for withstanding wind pressures of 100 miles per hour. Preferably, the coolant is liquid sodium-potassium eutectic alloy which will not normally freeze at night in the temperate zones, and when heated to 4,000° R exerts a pressure of only a few atmospheres.
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BACKGROUND
[0001] 1. Technical Field
[0002] The present disclosure relates generally to oil and gas wells, and more particularly to controlling gas leaking from an annular gap between surface and production casings thereof.
[0003] 2. Description of the Related Art
[0004] Historically, hydrocarbon wells for producing natural gas have been drilled using a larger diameter surface casing inside which is inserted a relatively smaller production casing that extends down into the production zone where the production casing is perforated to permit the production tubing to be fluidly coupled to the hydrocarbon source and control flow to the surface. According to Oil Country Tubular Goods “OCTG” standards, the surface casing typically has a diameter of 177.8 mm or 7 inches, while the production casing typically has a diameter of 114.3 mm or 4.5 inches. Once both casings are in place, the installer “cements” the annulus that exists between an interior of the surface casing and an exterior of the production casing, so as to prevent pressurization of the casings from the escape of gas up the annulus.
[0005] The importance of the problems associated with uncontrolled gas leaks is well documented. Uncontrolled gas leaks can also result from tubing and casing leaks, poor drilling practices, improper cement selection, inadequate zonal isolation and production cycling. Modern regulation of the oil and gas industry has resulted in the need to install surface casing vents, including retroactively installing surface casing vents on older wells. Many wells experience sustained casing pressure due to from the uncontrolled migration of gas to the surface, associated with annular flow which results from a number of causes, including inadequate cementation. With the increase in the importance, and hence value, of natural gas, gas leaks have become a very significant issue. For environmental and other reasons it is therefore desirable to find an affordable and safe way to control the migration of gas to the surface even in wells that are no longer producing on a commercial scale.
[0006] Previous attempts by the gas production industry to address the problem have concentrated on variations of a one-piece solution to sealing the annular gap. In one example, well owners attempted to weld steel plates onto the surface casing stub to seal the gap to the production casing. Disadvantageously, not all of the production casings were centered in the surface casing, so the solution would not work on all wells. Such an approach also presented significant safety issues. For instance, if a welder accidentally burned a hole in the production casing, then there could be an uncontrolled escape of gas leading to injuries and/or death. Further, since some of these wells are already venting natural gas up the annulus between the casings—welding is not an option at all.
[0007] Another example was to suspend production at the well, pull the production tubing, set a bridge plug, remove the production tubing spool, install a surface casing spool with a vent, then reinstall everything else. The cost of this was typically $25,000 to $35,000 per well. Such is a prohibitively costly approach, particularly for wells that are no longer producing on a commercial scale. Accordingly it is desirable to identify a way to seal and vent well-heads, which is both safe and cost-effective.
[0008] Devices sometimes known as “mud cans” were used while pulling tubing or drill pipes still filled with fluid. The mud can would be wrapped around the joint between 2 lengths of production tubing or drill pipe and then quick-latched to hold the device in place while breaking the joint to disconnect the pipes so that the fluid could drain through a port and out to a vacuum truck. Mud cans were not built to hold pressure, they were more like a funnel for redirecting drilling fluid while disassembling a drill string. The mud cans had the same size opening at each end and were always open to the vacuum truck, but the mud cans still leaked fluid around the edges. While mud cans appear similar in structure to some embodiments of the structures disclosed in the detailed description herein, the similarities are superficial and mud cans must not be confused with such structures. Mud cans are for use in a very different application and have very different operational specifications. Basically, the so-called mud can is for a temporary, non-sealing application and is small in volume and light-gauge in construction—such that it is completely unsuitable for the current application.
BRIEF SUMMARY
[0009] An apparatus to prevent uncontrolled escape of annular gas from well-heads may be summarized as including an elongate pressure vessel consisting of at least two mating shell portions, configured to be assembled around an upper-most point of intersection between a surface casing and a production casing installed at a well-head, the production casing positioned concentrically within the surface casing, to thereby form an annulus between the surface and the production casings, each of the shell portions respectively having a lower end and an upper end, each of the upper and the lower ends having a cover portion to enclose a cavity when the shell portions are matingly coupled to one another, each of the cover portions proximate the upper end of each shell portion having a respective portion of an upper opening that when the shell portions are assembled is sized to closely be received around the production casing, and each of the cover portions proximate the lower end of each shell portion having a respective portion of a lower opening that when the shell portions are assembled is sized to closely be received around the surface casing; a respective mating flange around a mating perimeter of each the shell portions to provide a surface to releaseably fasten the shell portions to one another to assemble the pressure vessel; a number of mating flange seals coupled to the mating flanges; a number of opening seals coupled to a perimeter of each of the first and the second openings; and a number of fasteners to selectively couple the flange on each shell portion to one another so as to sealingly assemble the elongate pressure vessel around the point of intersection with the cavity in fluid communication with the annulus.
[0010] The apparatus may further include a vent outlet through either mating shell portions; and a venting fluidly coupled to the cavity, and operable to control escape of accumulated annular gas from the pressure vessel. The pressure vessel may be a cylindrical tank when assembled. There may be more than two mating shell portions. One of the mating flanges may have a groove and the other one of the mating flanges may have a ridge sized to be sealingly received in the groove. The mating flange seal may include at least one of a PTFE joint-sealant tape. The number of fasteners may include a number of bolts and nuts.
[0011] The apparatus may further include an upper opening flange portion welded about a respective portion of the upper opening of each of the shell portions; and a lower opening flange portion welded about a respective portion of the lower opening of each of the shell portions. The respective shell portions may each include an upper opening flange portion and a lower opening flange portion which are unitary single piece constructions of the shell portions positioned about a respective portion of the upper and the lower openings of each of the shell portions.
[0012] A method of preventing the uncontrolled escape of annular gas from a well-head, the well-head having an annulus at the upper-most point of intersection between a surface casing and a production casing positioned concentrically within the surface casing thereby forming the annulus between the surface and production casings may be summarized as including installing at least a first seal around an exterior of the production casing above the point of intersection; installing at least a second seal around an exterior of the surface casing below the point of intersection; assembling a pressure vessel around the point of intersection, the pressure vessel forming an enclosed sealed cavity between the first seal around the exterior of the production casing and the second seal around the exterior of the surface casing; and allowing annular gas to collect inside the sealed cavity.
[0013] The method may further include controllably venting the collected annular gas from the pressure vessel; and measuring a flow of the annular gas vented so as to eliminate sustained casing pressure from the well-head.
[0014] An apparatus to prevent uncontrolled escape of annular gas from well-heads may be summarized as including an elongate pressure vessel consisting of at least two mating shell portions, configured to be assembled around an upper-most point of intersection between a surface casing and a production casing installed at a well-head, the production casing positioned concentrically within the surface casing, to form an annulus between the surface and the production casings, each of the shell portions respectively having a lower end and an upper end, each of the lower and the upper ends respectively having a cover portion to enclose a cavity when the shell portions are matingly coupled to one another; a mating flange around a mating perimeter of each the shell portions to allow fastening of the shell portions to one another to assemble the pressure vessel at the well-site; a TEADIT 24B PTFE joint-sealant tape positioned between opposing ones of the mating flanges when the shell portions are assembled to one another; a production casing receiving flange through each cover portion at the upper end of each shell portion, the production casing receiving flange having an inner radius of about 2.25 inches (114.3/2 mm), for assembly around a production casing installed at the well-head; a surface casing receiving flange through each cover portion at the lower end of each shell portion, the surface casing receiving flange having an inner radius of 3.5 inches (177.8/2 mm), for assembly around a surface casing installed at the well-head; a number of pieces of TEADIT 24B PTFE joint-sealant tape positionable between the production and the surface casing receiving flanges and the production and surface casings, respectively; and a number of fasteners to selectively fasten the mating flanges on each shell portion to adjacent ones of the shell portions to sealingly assemble the elongate pressure vessel around the point of intersection such that the cavity is in fluid communication with the annulus.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0015] In the drawings, identical reference numbers identify similar elements or acts. The sizes and relative positions of elements in the drawings are not necessarily drawn to scale. For example, the shapes of various elements and angles are not drawn to scale, and some of these elements are arbitrarily enlarged and positioned to improve drawing legibility. Further, the particular shapes of the elements as drawn, are not intended to convey any information regarding the actual shape of the particular elements, and have been solely selected for ease of recognition in the drawings.
[0016] FIG. 1 is a top, front, right side isometric view of a well-casing annular gas pressure seal and venting apparatus, according to one illustrated embodiment.
[0017] FIG. 2 is a front elevational view the well-casing annular gas pressure seal and venting apparatus of FIG. 1 .
[0018] FIG. 3 is a partial cross-sectional view of the well-casing annular gas pressure seal and venting apparatus of FIG. 2 , taken along a section line 3 - 3 in FIG. 2 .
[0019] FIG. 4 is top plan view of the well-casing annular gas pressure seal and venting apparatus of FIG. 1 .
[0020] FIG. 5 is an isometric view of an well-casing annular gas pressure seal and venting apparatus installed at a well-site, according to one illustrated embodiment.
DETAILED DESCRIPTION
[0021] In the following description, certain specific details are set forth in order to provide a thorough understanding of various disclosed embodiments. However, one skilled in the relevant art will recognize that embodiments may be practiced without one or more of these specific details, or with other methods, components, materials, etc. In other instances, well-known structures associated with well-sites have not been shown or described in detail to avoid unnecessarily obscuring descriptions of the embodiments.
[0022] Unless the context requires otherwise, throughout the specification and claims which follow, the word “comprise” and variations thereof, such as, “comprises” and “comprising” are to be construed in an open, inclusive sense, that is as “including, but not limited to.”
[0023] Reference throughout this 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. Thus, the appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. Further more, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.
[0024] 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. It should also be noted that the term “or” is generally employed in its sense including “and/or” unless the content clearly dictates otherwise.
[0025] The headings and Abstract of the Disclosure provided herein are for convenience only and do not interpret the scope or meaning of the embodiments.
[0026] FIG. 1 shows a well-casing annular gas pressure seal and venting apparatus denoted generally as 100 , according to one illustrated embodiment.
[0027] The well-casing annular gas pressure seal and venting apparatus includes a number of mating shell portions, for example mating half-shells 110 and 111 that are securely fastenable to one another by any suitable fasteners. As shown, first half-shell 110 is coupled (typically welded) to mating flange 140 having a series of holes 146 (not shown) through which bolts 145 may be inserted to mate mating flange 140 to mating flange 141 of second half-shell 111 . It is contemplated that other forms of fastener, such as rivets or suitable clamps and/or hinges may be used in place of the illustrated bolts. Each half-shell also has two opening flanges, (e.g., semi-circular flanges), one on each end of the half-shell 110 , 111 , projecting through top and bottom end cover portions (e.g., half-covers) 120 , 122 respectively, of half-shell 110 and top and bottom end cover portions (e.g., half-covers 121 , 123 ) ( FIG. 3 ) respectively, of half-shell 111 .
[0028] A corresponding pair of opening or semi-circular flanges 130 , 131 with an associated seal 134 , and pair of opening or semi-circular flanges 132 , 133 with an associated seal 135 ( FIG. 3 ), are constructed to sealingly engage well-casings (see FIG. 5 ) of different sizes. The pair of opening or semi-circular flanges 130 , 131 are each sized to closely accommodate OCTG standard production casing when the semi-circular flanges 130 , 131 are mated together. Thus the flanges 130 , 131 may be denominated as production casing receiving flanges. The pair of opening or semi-circular flanges 132 , 133 are sized to closely accommodate OCTG standard surface casing when the semi-circular flanges 132 , 133 are mated together. Thus, the flanges 132 , 133 may be denominated as surface casing receiving flanges.
[0029] When semi-circular flanges 130 and 131 are mated to one another, they form a toroid that seals the upper end of apparatus 100 tightly around the production casing so as to prevent annular gas from escaping apparatus 100 except through vent outlet 160 . At a lower end of apparatus 100 , semi-circular flanges 132 and 133 mate to form a toroid that seals the bottom of apparatus 100 tightly around a surface casing to prevent annular gas escape. Half-shells 110 and 111 are illustrated in a cylindrical profile, but it is understood that apparatus 100 will function substantially the same using other profiles such as rectangular, hexagonal, or elliptical.
[0030] FIG. 2 shows a half-shell assembly 200 .
[0031] The half-shell assembly 200 is comprised of half-shell 110 physically coupled to flange 140 , end half-covers 120 , 122 , and semi-circular flanges 130 , 132 , which are all visible together in FIG. 2 along with half-cavity 201 , from which gas may be vented via vent outlet 160 . The face 142 of the flange 140 may have any suitable number of holes 146 through which to apply mechanical fasteners to fasten half-shell 110 to half-shell 111 . The half-cavity 201 surrounds the point of intersection of the casings when installed. According to an alternate embodiment of apparatus 100 , half-shells 110 , 111 may be constructed with end half-covers 120 , 122 , 121 , 123 , respectively, sufficiently thick to act as flanges. Openings may be machined in the end half-covers 120 , 122 , having the same inner diameter as semi-circular flanges 130 and 132 respectively. Openings may be machined in the end half-covers 121 , 123 having the same inner diameter as semi-circular flanges 132 , 133 . The end half-covers may integrally form the flanges as an integral one piece construction, requiring no welding or other coupling acts. Such may eliminate the need to install any semi-circular flanges into the four end half-covers 120 , 121 , 122 , 123 of apparatus 100 .
[0032] To enhance the sealing effect of flanges 140 , 141 , as well as the toroids formed by the pairs of the semi-circular flange pairs 130 , 131 and 132 , 133 , seals 155 , 134 and 135 , respectively, may comprise any suitable material such as a gasket compound capable of conforming to complex or rough or pitted surfaces typically encountered on weather aged tubular elements at well-sites. According to one embodiment, seal 155 is a joint sealant such as that manufactured by W.L. Gore & Associates, Inc. Another suitable sealing product, manufactured by TALuft, is sold as TEADIT 24B, which is a PTFE joint-sealant tape capable of withstanding relatively high pressures (4200 kPa or 600 PSI) SCP without failure. Whether in the form of a tape, a gel compound, a pre-shaped sheet gasket, a form-in-place gasket, or any similar treatment or combination of the foregoing, the seal 155 applies to face 142 of planar flange 140 so as to prevent pressurized gas escape between flanges 140 and 141 . Similarly, seals 134 and 135 prevent pressurized gas escape between a production casing and pair of semi-circular end flanges 130 , 131 , and, a surface casing and pair of semi-circular end flanges 132 , 133 , respectively.
[0033] Flange 140 as illustrated is shown with face 142 having a simple planar design to which any suitable seal 155 may be applied to prevent annular gas leakage from shells 110 , 111 to whatever pressure level the local authorities specify. However, it is contemplated that flange 140 may be manufactured with interlocking elements such that there is a groove (not shown) on one half-shell and a corresponding ridge (not shown) on the other half-shell. Such may accommodate very high pressure applications. Such may be implemented with narrower flanges.
[0034] FIG. 3 shows the apparatus 100 in a partially cut-away side view.
[0035] In particular, a planar butt joint 305 between semi-circular flanges 130 , 131 is visible, as well as a butt joint 306 between semi-circular flanges 132 , 133 . However, it is similarly contemplated that joint configurations other than a planar joint may be employed. For example, either the semi-circular flanges or the openings in the half-shells may be manufactured with interlocking elements, such that there is a groove on one and a corresponding ridge on the other half-shell assembly, if needed or desired for any reason. Regardless of the particular sealing structure employed for a particular embodiment and installation, once sealed around the casings, apparatus 100 accumulates and contains annular gas in half-cavities 201 and 301 until vented. Also visible in FIG. 3 is a point 315 (vertical level) where surface casing 310 intersects production casing 320 inside the cavity formed by combining half-cavities 201 , 301 . Seals 135 , 134 are visible surrounding an exterior of surface casing 310 and production casing 320 , respectively.
[0036] FIG. 4 shows half-shells 110 , 111 fastened together using fasteners such as bolts 145 .
[0037] In particular, top seal 134 is visible along the inner circumference of the toroid formed by semi-circular flanges 130 & 131 .
[0038] In operation, apparatus 100 is installed over the well-site casings at the level, earlier identified by point 315 , where the surface and production casings begin to overlap at the top end of the surface casing. Apparatus 100 may be manufactured in any suitable length(s), but is typically approximately 2 feet long such that bottom semi-circular flanges 132 , 133 engage surface casing 310 approximately one foot below the upper end of the surface casing 310 at point 315 , while top semi-circular flanges 130 , 131 engage production casing 320 approximately one foot above that same level at point 315 . Such results in the “joint” being roughly vertically centered inside half-shells 110 , 111 . Prior to fastening half-shells 110 , 111 into position at any suitable level proximal point 315 , apparatus 100 may be adjusted vertically up or down to ensure that all semi-circular flanges are positioned over straight segments of undamaged exterior face on their respective casings. Such permits an effective gas tight seal of annular gas inside cavity 201 , 301 . At a site where either or both casings are damaged over a vertical span sufficient to prevent sealing a standard length version of apparatus 100 , it is to be understood that an extended custom length apparatus 100 (working in the same manner) can be manufactured so as to reach far enough along the casings to permit the installer to seal around undamaged segments of each casing.
[0039] FIG. 5 shows the apparatus 100 installed at a typical well-site 500 , according to one illustrated embodiment.
[0040] The apparatus 100 enclosing point 315 being at the level of intersection (not visible) between surface casing 310 and production casing 320 through which casing, production tubing (not shown) delivers a hydrocarbon flow to any suitable valve assembly 520 . Vent assembly 510 is fluidly coupled to vent outlet 160 to permit a well operator to periodically monitor, measure flow rates, and divert annular gas accumulated in apparatus 100 , so as to release any sustained pressure therein. Conventional monitor or measuring equipment, for example gas flow meters may be employed.
[0041] The above description of illustrated embodiments, including what is described in the Abstract, is not intended to be exhaustive or to limit the embodiments to the precise forms disclosed. Although specific embodiments of and examples are described herein for illustrative purposes, various equivalent modifications can be made without departing from the spirit and scope of the disclosure, as will be recognized by those skilled in the art of gas flow control. The teachings provided herein of the various embodiments can be applied to other apparatus that control gas flow at well sites, not necessarily the exemplary well-casing annular gas pressure seal and venting apparatus generally described above.
[0042] For example, while illustrated as two mating halves, the apparatus may include more than two portions which mate together in a similar fashion to the two mating halves. Also for example, while illustrated as employing a circular cross-section, other geometric shapes may be employed.
[0043] The various embodiments described above can be combined to provide further embodiments. To the extent that they are not inconsistent with the specific teachings and definitions herein, all commonly assigned U.S. patents, U.S. patent application publications, U.S. patent applications, referred to in this specification and/or listed in the Application Data Sheet are incorporated herein by reference, in their entirety. Aspects of the embodiments can be modified, if necessary, to employ structures and concepts of the various patents and applications to provide yet further embodiments.
[0044] These and other changes can be made to the embodiments in light of the above-detailed description. In general, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification and the claims, but should be construed to include all possible embodiments along with the full scope of equivalents to which such claims are entitled. Accordingly, the claims are not limited by the disclosure.
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Disclosed apparatus and methods permit well-site operators to retrofit existing wells in order to comply with local regulations that restrict the escape of annular natural gas from hydrocarbon wells. Such allows sealing around an exterior of surface and concentric production casings, both above and below the point of their intersection, then assembling a pressure vessel around that point and between those seals so as to capture and hold gas rising up an intercasing annulus, for periodic controlled venting.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a transmission system comprising a first station connected to a second station by a transmission channel, each station comprising a transmitter and a receiver, at least the first station comprising an echo canceller arrangement which includes an adaptive filter for generating, on the basis of data transmitted by the transmitter, a replica of an echo present in the input signal of the receiver, and a subtracter circuit for supplying to the receiver the difference between the input signal and the echo replica. The adaptive filter is arranged for determining the echo replica by calculating a sum weighted with weight factors of the transmitted data as delayed by multiples of a time period T.
2. Description of the Related Art
Such echo canceller arrangements are well known and find important applications in the field of telephone transmissions and data transmission. The echoes are most frequently due to mismatches caused by the 2-wire/4-wire transitions situated between a near-end speaker and a far-end speaker. In the field of telephone transmissions, the more distant the echo is, the more noticable it becomes. This effect of distance is enhanced in the digital teIephone systems, which may introduce additional delays caused by the fact that a certain period of time is devoted to packetizing the speech signals.
For adjusting the weight factors one often uses the sign method. This method is described, more specifically, in paragraph IV.7 of the article by M. BELLANGER entitled: "ANALYSE DES SIGNAUX ET FILTRAGE NUMERIQUE ADAPTIF", published in 1989 by MASSON, PARIS. This method, which utilizes nonstationary signals, such as speech signals does have some drawbacks, however. It corrects the factors by adding thereto or subtracting therefrom a fixed quantity. This value is either low, and so the convergence of the factors to their optimum value is slow, or is high and so there is a risk of instability.
SUMMARY OF THE INVENTION
The present invention proposes an echo canceller arrangement which largely eliminates the drawbacks of the aforesaid prior art sign method.
Such arrangement is characterized in that it includes a calculation circuit to determine new values of at least one weight factor on the basis of the original value of the weight factor and a correction term which term is proportional to the weight factor, and to determine the correlation between the value of the delayed data multiplied by this weight factor and the difference between the input signal and the echo replica.
Preferably d will be selected to be d=2 -m , where m is an integer. Thus, the multiplication by this value may be made by a simple shift, which facilitates the realization and the rapidity of the process.
BRIEF DESCRIPTION OF THE DRAWINGS
The following description, accompanied by the appended drawings, will be given by way of non-limiting example, and will make it better understood how the invention may be realized. In the drawings:
FIG. 1 represents a basic circuit diagram of the invention,
FIG. 2 represents the circuit diagram of an echo canceller used in the arrangement according to the invention,
FIG. 3 represents a construction scheme of an arrangement according to the invention, and
FIGS. 4 to 6 are operation flow charts of the arrangement shown in FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1 the echo canceller arrangement lie in the fixed part or base unit 5 of a DECT system defined by the ETSI as a cordless telephone system (cf. contribution ETS 300 175-8). The fixed part 5 is connected by a hybrid transformer 10 therein to a two-wire output line 8 which is connected to a switching centre 6. The hybrid transformer 10 separates the outgoing channel A from the return channel R. Channel A includes an analog-digital converter 12 and channel B includes a digital-analog converter 14. These converters work with linear digital samples, that is to say, they linearly code the analogue magnitude they represent, so that the echo canceller arrangement 1 works with linear digital samples. A code converter 16, inserted into the outgoing channel A, transforms this linear code into a differential code which is more suitable to process by a radio section 18 of the installation 5. A decoder 20 carries out the reverse operation in the return channel R.
The DECT installation also includes a mobile unit 30 to which a combination of subscribers 32 are connected. Two aerials 34 and 36 allocated to the mobile and the fixed part respectively, make it possible to form radio links for exchanging information between the two parts.
The echo canceller arrangement 1 is diagrammatically represented by an echo synthesizer 50 which comprises an adjustment control 52 and a subtracter circuit 54 which subtracts at the instant "i" a synthesized echo signal r'(i) from the signal supplied by the converter 12. The aim of this signal r'(i) is to cancel the echo r(i) caused, more specifically, by the hybrid transformer 10. The annoying effect of this echo is amplified by the delays caused by the fixed and mobile parts. The synthesizer is thus adjusted to cancel as much as possible the echo signal r(i) from the output of the circuit 54.
FIG. 2 shows an operation circuit diagram of the echo canceller arrangement i and also of the echo synthesizer 50. The latter is formed by a succession of delay elements 70 1 , . . . , 70 N , which each bring about a delay having a value T which corresponds to successive time period at which the samples produced by the converter 12 appear. Various multiplier circuits 80 0 , 80 1 , . . . , 80 N multiply by weight factors c 0 , c 1 , . . . , c N respectively, the sample at the input of the circuit 70 1 and the various samples at the output of the other circuits . . . , 70 N . An arithmetic circuit 85 determines the factors c 0 , c 1 , . . . , C N in response to the output signal of the subtracter circuit 54. The output signals of the converters 12 and 20 are also used, but to a less fundamental degree, for adjusting these factors. A summing circuit 90 produces the synthesized echo by adding together all the results produced by the various multiplier circuits 80 0 , 80 1 , . . . , 80 N .
According to the invention, to determine these various factors c 0 , c 1 , . . . , c N , the arithmetic circuit 85 operates in the following manner:
the summing circuit 90 produces the synthesized echo r': ##EQU1## the coefficients c k (i) are given by:
c.sub.k (i+1)=c.sub.k (i)(1+d·sign[x(i-k)·u(i)])(2)
in this formula:
the sign function [. .]adopts the "+1" or "-1" value according to the sign of the argument.
u(i)-y(i)+r(i)-r'(i) (3)
d=2 -m , where m is an integer.
FIG. 3 shows a construction scheme of an arrangement according to the invention. This arrangement is built around a microprocessor ensemble 100 formed by an actual microprocessor, a read/write memory for containing various specifically intermediate data and also by a read only memory for containing, for example, the operation program. This ensemble may be formed by a signal processor of the TMS320 type. In the scheme shown in FIG. 3 various access ports connected to registers 101, 102 and 103 necessary for the operation of the arrangement 1 are shown in detail, whereas these registers are in fact incorporated in the same housing. Register 101 is intended to receive the samples produced by converter 12, register 102 is intended to receive the samples produced by converter 20 and register 103 is to contain the samples for converter 16. Reference 150 is a clock producing signals at the sample rate: 1/T. This clock is connected to an interrupt input 160, so that an interrupt routine can be carried out for each sample.
FIG. 4 shows part of the operation flow chart of an arrangement according to the invention. Box K0 shows the start of the program. Box K1 is an initialization phase where various variables receive their initial value. To provide that the rest of the program can be carried out, it is necessary that an interrupt signal produced by the clock 150 occurs which is indicated in box K2. Box K5 indicates the incrementation of the contents of an interrupt counter "cpint", after which, in box K6, the value x(0) is read out which value x(0) is contained in register 102. In box K7 the value of the amplitude x(4) is tested against a level value NIVX. It should be observed that the samples x(0), x(1), x(2), x(3) are not affected by the rest of the process. These four samples correspond to the delays with which the echo appears. The process thus commences with an examination of the level of the signal x(4). There is examined whether the amplitude of this signal x(4) in an absolute value exceeds the level NIVX by a certain factor FACO. There is also examined whether this level NIVX exceeds -42 dBm0. These two conditions are shown in box K7. If these conditions are not satisfied, the value 0 is assigned to a variable x c (0), if these conditions are satisfied, branch Y is taken, which is a test of box K7, and the value x(4) is examined in box K10. If the value x(4) exceeds 0, branch Y is taken and the value +1 is assigned to the value x c (0). If this value is negative, the value -1 is assigned to the variable x c (0) in box K11. Thus, the evaluation of the sign function has already been commenced. From boxes K8, K11 and K12 one proceeds to box K15 where the synthesized echo r'(i) is evaluated in accordance with formula (1). Box K17 indicates the reading of a variable RIN, this variable being contained in the register 101, so that it is possible in box K20 to evaluate a quantity ROUT which represents the signal whose echo has been suppressed. The formula indicated in box K20 is to be compared with formula (3). Then, the value ROUT calculated in this manner is loaded into the register 103. This is indicated in box K22. Afterwards, in box K24, various variables relating to the signal levels defined by the contents of the registers 101, 102 and 103, NIX, NIRI, NIRD are updated. Box K26, which follows is the examination of various conditions: there is examined whether the flag GCOP is equal to 0, whether the absolute value of the signal ROUT is higher than -60 dBm0, whether this value is higher than NIVX-42 dB and whether "m" has either value SLOW or FAST. If these conditions are not fulfilled, box K30 of FIG. 5 is proceeded to.
This box K30 indicates a test of the value m. If value m has two functions: a first function is to contain the value of a convergence parameter SLOW or FAST, and the second function (m adopts the value -1) is to indicate a divergence of the algorithm. If this value is equal to -1, there is thus divergence, box K32 is proceeded to, where the values c k are set to 0. Then, in box K34, the value "m" adopts the value FAST, so that the convergence of the formula (2) is faster. If the conditions shown in box K26 are fulfilled, box K40 of FIG. 5 is proceeded to. Box K40 indicates a test of the value ROUT. If this value is positive, branch Y is taken to go to box K42. There, the value of the factors c k is modified by a sign value "+", that is +2 -m ·x c (k). If this value is negative, box K44 is proceeded to, where the value c k is corrected to a negative value -2 -m ·x c (k). There should be observed that a low value equal to the least significant bit (LSB) has systematically been added; this to ensure the coefficient development. Once the operations indicated in one of the boxes K34, K42 and K44 have been carried out, box K50 is proceeded to. Box KS0 indicates the shift operation of the various samples x(k), where k varies from 0 to N+4 and the shift of the associated signs x c (k), where k varies from 0 to N. Then box K52 is proceeded to, where the number of interruptions are counted. If this figure is not equal to 32, branch N is taken and box K55 is proceeded to, which indicates the end of the interrupt program. If this value is indeed equal to 32, branch Y is taken and box K60 is proceeded to. Worded differently, the operations which follow are carried out once per 32 initiated interruptions. This box K60 resumes counting interruptions when "cpint" equals zero. The rest of the process is shown in FIG. 6.
Box K70 of FIG. 6 shows an updating of the various levels NIVX, NIVRI, NIVRO. Box K72 reinitializes various values NIX, NIRI and NIRO used for updating previous levels. Finally, one proceeds to box KS0. This box KS0 indicates tests which show the eventuality of a divergence of the algorithm. First NIVRO is tested against a level of -40 dBmO, this level is also tested to find whether it is higher than a factor FAC1 for the level NIVRI. If these conditions are fulfilled, there is thus a tendency towards divergence. Branch Y is taken and box K82 is proceeded to. Here a divergence counter "cpdiv" is incremented by unity. In box K84 the contents of this counter are compared with a certain value "ms" which corresponds to a time period of various milliseconds. If these contents exceed the value "ms", there is thus divergence. The divergence counter is set to 0 and "m" is set to -1 to indicate that there is divergence, and this value will be used at the next interrupt call. If the conditions indicated in box KS0 are not fulfilled, branch N is taken and box K88 is proceeded to, where the divergence counter "cpdiv" is set to 0. The tests of box K90 relate to the detection of the beginning of the convergence of the algorithm. This is represented in box K90 where the case is examined where NIVRO is higher than a factor FAC2 for the level NIVRI. There is examined whether this level NIVRO is higher than -42 dBm0 and there is also examined whether the factor "m" is equal to FAST. If the conditions of box K90 are fulfilled, then "m" adopts the value SLOW in box K92. If these conditions of box K90 are not fulfilled, box K100 is proceeded to. Box K100 is also proceeded to once the assignment shown in box K92 has been made. If the subscriber speaks in the receiver 32 (this the case of doubletalk), it goes without saying that the echo canceller can be rendered defective by the signals brought about by this subscriber. This condition is thus to be detected (see box K100). If the test of box K100 gives a satisfactory result, box K102 is proceeded to where the flag GCOP is set to the value 1. If this test does not produce a satisfactory result, box K104 is proceeded to, where two conditions are verified; the first: does m have the value SLOW, the second: does NIVRO exceed the value NIVRI by a factor FAC4. If so, the flag GCOP adopts the value 1 in box K106. If not, the flag GCOP adopts the value 0 in box K108. Thus the program is terminated at box K110.
The factors FAC0, FAC1, FAC2, FAC3 and FAC4 are selected in such a way that they correspond to the values below:
FACO: 0 dB
FAC1: ±1 dB
FAC2: -12 dB
FAC3: +6 dB
FAC4: -9 dB
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An echo canceller arrangement (1) receives data x(i) which are likely to generate an echo r(i), and data y(i)+r(i) affected by the echo. An echo synthesizer (50) forms a replica r'(i) of the echo r(i) on the basis of a series of data delayed by delay elements 70 1 . . . 70 N and weighted by weight factors c k , where k=1, . . . , N. An arithmetic element (85) determines the factors c k according to:
c.sub.k (i+1)=c.sub.k (i)+d·c.sub.k
(i)·sign[x(i-k)·e(i)] where d<1.
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RELATED APPLICATIONS
This application is a continuation of U.S. Ser. No. 09/288,357 filed Apr. 8, 1999, now U.S. Pat. No. 5,981,693, which is a continuation of U.S. Ser. No. 09/129,286 filed Aug. 5, 1998, now U.S. Pat. No. 5,917,007, which is a continuation of U.S. Ser. No. 08/910,692 filed Aug. 13, 1997, now abandoned, which is a divisional of U.S. Ser. No. 08/460,980 filed on Jun. 5, 1995, now U.S. Pat. No. 5,679,717, which is a continuation-in-part of U.S. Ser. No. 08/258,431 filed Jun. 10, 1994, now abandoned, the entire teachings of all of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
This invention relates to removing bile salts from a patient.
Salts of bile acids act as detergents to solubilize and consequently aid in digestion of dietary fats. Bile acids are precursors to bile salts, and are derived from cholesterol. Following digestion, bile acids can be passively absorbed in the jejunum, or, in the case of conjugated primary bile acids, reabsorbed by active transport in the ileum. Bile acids which are not reabsorbed by active transport are deconjugated and dehydroxylated by bacterial action in the distal ileum and large intestine.
Reabsorption of bile acids from the intestine conserves lipoprotein cholesterol in the bloodstream. Conversely, blood cholesterol level can be diminished by reducing reabsorption of bile acids.
One method of reducing the amount of bile acids that are reabsorbed is oral administration of compounds that sequester the bile acids and cannot themselves be absorbed. The sequestered bile acids consequently either decompose by bacterial action or are excreted.
Many bile acid sequestrants, however, bind relatively hydrophobic bile acids more avidly than conjugated primary bile acids, such as conjugated cholic and chenodeoxycholic acids. Further, active transport in the ileum causes substantial portions of sequestered conjugated primary bile acids to be desorbed and to enter the free bile acid pool for reabsorption. In addition, the volume of sequestrants that can be ingested safely is limited. As a result, the effectiveness of sequestrants to diminish blood cholesterol levels is also limited.
Sequestering and removing bile salts (e.g., cholate, glycocholate, glycochenocholate, taurocholate, and deoxycholate salts) in a patient can be used to reduce the patient's cholesterol level. Because the biological precursor to bile salt is cholesterol, the metabolism of cholesterol to make bile salts is accompanied by a simultaneous reduction in the cholesterol in the patient.
Cholestyramine, a polystyrene/divinylbenzene ammonium ion exchange resin, when ingested, removes bile salts via the digestive tract. This resin, however, is unpalatable, gritty and constipating. Resins which avoid (totally or partially) these disadvantages and/or possess improved bile salt sequestration properties are needed.
SUMMARY OF THE INVENTION
The invention relates to the discovery that a new class of ion exchange resins have improved bile salt sequestration properties and little to no grittiness, thereby improving the palatability of the composition.
The resins comprise cross-linked polyamines which are characterized by one or more hydrophobic substituents and, optionally, one or more quaternary ammonium containing substituents.
In general, the invention features resins and their use in removing bile salts from a patient that includes administering to the patient a therapeutically effective amount of the reaction product of:
(a) one or more crosslinked polymers, salts and copolymers thereof characterized by a repeat unit selected from the group consisting essentially of: ##STR1##
(NR--CH.sub.2 CH.sub.2).sub.n (3)
(NR--CH.sub.2 CH.sub.2 --NR--CH.sub.2 CH.sub.2 --NR--CH.sub.2 CHOH--CH.sub.2).sub.n (4)
where n is a positive integer and each R, independently, is H or a substituted or unsubstituted alkyl group (e.g., C 1 -C 8 alkyl); and
(b) at least one alkylating agent. The reaction product is characterized in that: (i) at least some of the nitrogen atoms in the repeat units are unreacted with the alkylating agent; (ii) less than 10 mol % of the nitrogen atoms in the repeat units that react with the alkylating agent form quaternary ammonium units; and (iii) the reaction product is preferably non-toxic and stable once ingested.
Suitable substituents include quaternary ammonium, amine, alkylamine, dialkylamine, hydroxy, alkoxy, halogen, carboxamide, sulfonamide and carboxylic acid ester, for example.
In preferred embodiments, the polyamine of compound (a) of the reaction product is crosslinked by means of a multifunctional crosslinking agent, the agent being present in an amount from about 0.5-25% (more preferably about 2.5-20% (most preferably 1-10%)) by weight, based upon total weight or monomer plus crosslinking agent. A preferred crosslinking agent is epichlorohydrin because of its high availability and low cost. Epichlorohydrin is also advantageous because of it's low molecular weight and hydrophilic nature, increasing the water-swellability and gel properties of the polyamine.
The invention also features compositions based upon the above-described reaction products.
The invention provides an effective treatment for removing bile salts from a patient (and thereby reducing the patient's cholesterol level). The compositions are non-toxic and stable when ingested in therapeutically effective amounts.
Other features and advantages will be apparent from the following description of the preferred embodiments thereof and from the claims.
DETAILED DESCRIPTION OF THE INVENTION
Compositions
Preferred reaction products include the products of one or more crosslinked polymers having the formulae set forth in the Summary of the Invention, above, and one or more alkylating agents. The polymers are crosslinked. The level of crosslinking makes the polymers completely insoluble and thus limits the activity of the alkylated reaction product to the gastrointestinal tract only. Thus, the compositions are non-systemic in their activity and will lead to reduced side-effects in the patient.
By "non-toxic" it is meant that when ingested in therapeutically effective amounts neither the reaction products nor any ions released into the body upon ion exchange are harmful. Cross-linking the polymer renders the polymer substantially resistant to absorption. When the polymer is administered as a salt, the cationic counterions are preferably selected to minimize adverse effects on the patient, as is more particularly described below.
By "stable" it is meant that when ingested in therapeutically effective amounts the reaction products do not dissolve or otherwise decompose in vivo to form potentially harmful by-products, and remain substantially intact so that they can transport material out of the body.
By "salt" it is meant that the nitrogen group in the repeat unit is protonated to create a positively charged nitrogen atom associated with a negatively charged counterion.
By "alkylating agent" it is meant a reactant which, when reacted with the crosslinked polymer, causes an alkyl group or derivative thereof (e.g., a substituted alkyl, such as an aralkyl, hydroxyalkyl, alkylammonium salt, alkylamide, or combination thereof) to be covalently bound to one or more of the nitrogen atoms of the polymer.
One example of preferred polymer is characterized by a repeat unit having the formula ##STR2## or a salt or copolymer thereof; wherein x is zero or an integer between about 1 to 4.
A second example of a preferred polymer is characterized by a repeat unit having the formula
(NH--CH.sub.2 CH.sub.2).sub.n (6)
or a salt or copolymer thereof.
A third example of a preferred polymer is characterized by a repeat unit having the formula
(NH--CH.sub.2 CH.sub.2 --NH--CH.sub.2 CH.sub.2 --NH--CH.sub.2 CHOH--CH.sub.2).sub.n (7)
or a salt or copolymer thereof.
The polymers are preferably crosslinked prior to alkylation. Examples of suitable crosslinking agents include acryloyl chloride, epichlorohydrin, butanedioldiglycidyl ether, ethanedioldiglycidyl ether, and dimethyl succinate. The amount of crosslinking agent is typically between 0.5 and 25 weight %, based upon combined weight of crosslinking agent and monomer, with 2.5-20%, or 1-10%, being preferred.
Typically, the amount of crosslinking agent that is reacted with the amine polymer is sufficient to cause reaction of between about 0.5 and twenty percent of the amines. In a preferred embodiment, between about 0.5 and six percent of the amine groups react with the crosslinking agent.
Crosslinking of the polymer can be achieved by reacting the polymer with a suitable crosslinking agent in an aqueous caustic solution at about 25° C. for a period of time of about eighteen hours to thereby form a gel. The gel is then combined with water and blended to form a particulate solid. The particulate solid can then be washed with water and dried under suitable conditions, such as a temperature of about 50° C. for a period of time of about eighteen hours.
Alkylation involves reaction between the nitrogen atoms of the polymer and the alkylating agent (which may contain additional nitrogen atoms, e.g., in the form of amido or ammonium groups). In addition, the nitrogen atoms which do react with the alkylating agent(s) resist multiple alkylation to form quaternary ammonium ions such that less than 10 mol % of the nitrogen atoms form quaternary ammonium ions at the conclusion of alkylation.
Preferred alkylating agents have the formula RX where R is a C 1 -C 20 alkyl (preferably C 4 -C 20 ), C 1 -C 20 hydroxy-alkyl (preferably C 4 -C 20 hydroxyalkyl), C 7 -C 20 aralkyl, C 1 -C 20 alkylammonium (preferably C 4 -C 20 alkyl ammonium), or C 1 -C 20 alkylamido (preferably C 4 -C 20 alkyl amido) group and X includes one or more electrophilic leaving groups. By "electrophilic leaving group" it is meant a group which is displaced by a nitrogen atom in the crosslinked polymer during the alkylation reaction. Examples of preferred leaving groups include halide, epoxy, tosylate, and mesylate group. In the case of, e.g., epoxy groups, the alkylation reaction causes opening of the three-membered epoxy ring.
Examples of preferred alkylating agents include a C 1 -C 20 alkyl halide (e.g., an n-butyl halide, n-hexyl halide, n-octyl halide, n-decyl halide, n-dodecyl halide, n-tetradecyl halide, n-octadecyl halide, and combinations thereof); a C 1 -C 20 dihaloalkane (e.g., a 1,10-dihalodecane); a C 1 -C 20 hydroxyalkyl halide (e.g., an 11-halo-1-undecanol); a C 1 -C 20 aralkyl halide (e.g., a benzyl halide); a C 1 -C 20 alkyl halide ammonium salt (e.g., a (4-halobutyl) trimethylammonium salt, (6-halohexyl)trimethyl-ammonium salt, (8-halooctyl)trimethylammonium salt, (10-halodecyl)trimethylammonium salt, (12-halododecyl)-trimethylammonium salts and combinations thereof); a C 1 -C 20 alkyl epoxy ammonium salt (e.g., a (glycidylpropyl)-trimethylammonium salt); and a C 1 -C 20 epoxy alkylamide (e.g., an N-(2,3-eoxypropane)butyramide, N-(2,3-epoxypropane) hexanamide, and combinations thereof).
It is particularly preferred to react the polymer with at least two alkylating agents, added simultaneously or sequentially to the polymer. In one preferred example, one of the alkylating agents has the formula RX where R is a C 1 -C 20 alkyl group and X includes one or more electrophilic leaving groups (e.g., an alkyl halide), and the other alkylating agent has the formula R'X where R' is a C 1 -C 20 alkyl ammonium group and X includes one or more electrophilic leaving groups (e.g., an alkyl halide ammonium salt).
In another preferred example, one of the alkylating agents has the formula RX where R is a C 1 -C 20 alkyl group and X includes one or more electrophilic leaving groups (e.g., an alkyl halide), and the other alkylating agent has the formula R'X where R' is a C 1 -C 20 hydroxyalkyl group and X includes one or more electrophilic leaving groups (e.g., a hydroxy alkyl halide).
In another preferred example, one of the alkylating agents is a C 1 -C 20 dihaloalkane and the other alkylating agent is a C 1 -C 20 alkylammonium salt.
The reaction products may have fixed positive charges, or may have the capability of becoming charged upon ingestion at physiological pH. In the latter case, the charged ions also pick up negatively charged counterions upon ingestion that can be exchanged with bile salts. In the case of reaction products having fixed positive charges, however, the reaction product may be provided with one or more exchangeable counterions. Examples of suitable counterions include Cl - , Br - , CH 3 OSO 3 - , HSO 4 - , SO 4 2- , HCO 3 - , CO 3 - , acctate, lactate, succinate, propionate, butyrate, ascorbate, citrate, maleate, folate, an amino acid derivative, a nucleotide, a lipid, or a phospholipid. The counterions may be the same as, or different from, each other. For example, the reaction product may contain two different types of counterions, both of which are exchanged for the bile salts being removed. More than one reaction product, each having different counterions associated with the fixed charges, may be administered as well.
The alkylating agent can be added to the cross-linked polymer at a molar ratio between about 0.05:1 to 4:1, for example, the alkylating agents can be preferably selected to provide hydrophobic regions and hydrophilic regions.
The amine polymer is typically alkylated by combining the polymer with the alkylating agents in an organic solvent. The amount of first alkylating agent combined with the amine polymer is generally sufficient to cause reaction of the first alkylating agent with between about 5 and 75 of the percent of amine groups on the amine polymer that are available for reaction. The amount of second alkylating agent combined with the amine polymer and solution is generally sufficient to cause reaction of the second alkylating agent with between about 5 and about 75 of the amine groups available for reaction on the amine polymer. Examples of suitable organic solvents include methanol, ethanal, isopropanol, acetonitrile, DMF and DMSO. A preferred organic solvent is methanol.
In one embodiment, the reaction mixture is heated over a period of about forty minutes to a temperature of about 65° C. with stirring. Typically, an aqueous sodium hydroxide solution is continuously added during the reaction period. Preferably, the reaction period at 65 ° C. is about eighteen hours, followed by gradual cooling to a room temperature of about 25° C. over a period of about four hours. The resulting reaction product is then filtered, resuspended in methanol, filtered again, and then washed with a suitable aqueous solution, such as two molar sodium chloride,and then with deionized water. The resultant solid product is then dried under suitable conditions, such as at a temperature of about 60° C. in an air-drying oven. The dried solid can then be subsequently processed. Preferably, the solid is ground and passed through an 80 mesh sieve.
In a particularly preferred embodiment of the invention, the amine polymer is a crosslinked poly(allylamine), wherein the first substituent includes a hydrophobic decyl moiety, and the second amine substituent includes a hexyltrimethylammonium. Further, the particularly preferred crosslinked poly(allylamine) is crosslinked by epichlorohydrin that is present in a range of between about two and six percent of the amines available for reaction with the epichlorohydrin.
The invention will now be described more specifically by the examples.
EXAMPLES
A. Polymer Preparation
1. Preparation of Poly (vinylaminc)
The first step involved the preparation of ethylidenebisacetamide. Acetamide (118 g), acetaldehyde (44.06 g), copper acetate (0.2 g), and water (300 mL) were placed in a 1 L three neck flask fitted with condenser, thermometer, and mechanical stirred. Concentrated HCl (34 mL) was added and the mixture was heated to 45-50° C. with stirring for 24 hours. The water was then removed in vacuo to leave a thick sludge which formed crystals on cooling to 5° C. Acetone (200 mL) was added and stirred for a few minutes, after which the solid was filtered off and discarded. The acetone was cooled to 0° C. and solid was filtered off. This solid was rinsed in 500 mL acetone and air dried 18 hours to yield 31.5 g of ethylidenebis-acetamide.
The next step involved the preparation of vinylacetamide from ethylidenebisacetamide. Ethylidenebisacetamide (31.05 g), calcium carbonate (2 g) and celite 541 (2 g) were placed in a 500 mL three neck flask fitted with a thermometer, a mechanical stirred, and a distilling heat atop a Vigroux column. The mixture was vacuum distilled at 24 mm Hg by heating the pot to 180-225° C. Only a single fraction was collected (10.8 g) which contained a large portion of acetamide in addition to the product (determined by NMR). This solid product was dissolved in isopropanol (30 mL) to form the crude vinylacetamide solution used for polymerization.
Crude vinylacetamide solution (15 mL), divinylbenzene (1 g, technical grade, 55% pure, mixed isomers), and AIBN (0.3 g) were mixed and heated to reflux under a nitrogen atmosphere for 90 minutes, forming a solid precipitate. The solution was cooled, isopropanol (50 mL) was added, and the solid was collected by centrifugation. The solid was rinsed twice in isopropanol, once in water, and dried in a vacuum oven to yield 0.8 g of poly(vinylacetamide), which was used to prepare poly(vinylamine as follows).
Poly(vinylacetamide) (0.79 g) was placed in a 100 mL one neck flask containing water (25 mL) and conc. HCl (25 mL). The mixture was refluxed for 5 days, after which the solid was filtered off, rinsed once in water, twice in isopropanol, and dried in a vacuum oven to yield 0.77 g of product. Infrared spectroscopy indicated that a significant amount of the amide (1656 cm -1 ) remained and that not much amine (1606 cm -1 ) was formed. The product of this reaction (˜0.84 g) was suspended in NaOh (46 g) and water (46 g) and heated to boiling (˜140° C.). Due to foaming the temperature was reduced and maintained at ˜100° C. for 2 hours. Water (100 mL) was added and the solid collected by filtration. After rinsing once in water the solid was suspended in water (500 mL) and adjusted to pH 5 with acetic acid. The solid was again filtered off, rinsed with water, then isopropanol, and dried in a vacuum oven to yield 0.51 g of product. Infrared spectroscopy indicated that significant amine had been formed.
2. Preparation of Poly(ethyleneimine)
Polyethyleneimine (120 g of a 50% aqueous solution; Scientific Polymer Products) was dissolved in water (250 mL). Epichlorohydrin (22.1 mL) was added dropwise. The solution was heated to 60° C. for 4 hours, after which it had gelled. The gel was removed, blended with water (1.5 L) and the solid was filtered off, rinsed three times with water (3 L) and twice with isopropanol (3 L), and the resulting gel was dried in a vacuum oven to yield 81.2 g of the title polymer.
3. Preparation of Poly(allylamine) hydrochloride
To a 2 liter, water-jacketed reaction kettle equipped with (1) a condenser topped with a nitrogen gas inlet, (2) a thermometer, and (3) a mechanical stirrer was added concentrated hydrochloric acid (360 mL). The acid was cooled to 5° C. using circulating water in the jacket of the reaction kettle (water temperature=0° C.). Allylamine (328.5 mL, 250 g) was added dropwise with stirring while maintaining the reaction temperature at 5-10° C. After addition was complete, the mixture was removed, placed in a 3 liter one-neck flask, and 206 g of liquid was removed by rotary vacuum evaporation at 60° C. Water (20 mL) was then added and the liquid was returned to the reaction kettle. Azobis(amidinopropane) dihydrochloride (0.5 g) suspended in 11 mL of water was then added. The resulting reaction mixture was heated to 50° C. under a nitrogen atmosphere with stirring for 24 hours. Additional azobis(amidinopropane) dihydrochloride (5 mL) suspended in 11 mL of water was then added, after which heating and stirring were continued for an additional 44 hours.
At the end of this period, distilled water (100 mL) was added to the reaction mixture and the liquid mixture allowed to cool with stirring. The mixture was then removed and placed in a 2 liter separatory funnel, after which it was added dropwise to a stirring solution of methanol (4 L), causing a solid to form. The solid was removed by filtration, re-suspended in methanol (4 L), stirred for 1 hour, and collected by filtration. The methanol rinse was then repeated one more time and the solid dried in a vacuum oven to afford 215.1 g of poly(allylamine) hydrochloride as a granular white solid.
4. Preparation of Poly(allylamine) hydrochloride Crosslinked with epichlorohydrin
To a 5 gallon vessel was added poly(allylamine) hydrochloride prepared as described in Example 3 (1 kg) and water (4 L). The mixture was stirred to dissolve the hydrochloride and the pH was adjusted by adding solid NaOH (284 g). The resulting solution was cooled to room temperature, after which epichlorohydrin crosslinking agent (50 mL) was added all at once with stirring. The resulting mixture was stirred gently until it gelled (about 35 minutes). The crosslinking reaction was allowed to proceed for an additional 18 hours at room temperature, after which the polymer gel was removed and placed in portions in a blender with a total of 10 L of water. Each portion was blended gently for about 3 minutes to form coarse particles which were then stirred for 1 hour and collected by filtration. The solid was rinsed three times by suspending it in water (10 L, 15 L, 20 L), stirring each suspension for 1 hour, and collecting the solid each time by filtration. The resulting solid was then rinsed once by suspending it in isopropanol (17 L), stirring the mixture for 1 hour, and then collecting the solid by filtration, after which the solid was dried in a vacuum oven at 50° C. for 18 hours to yield about 677 g of the cross linked polymer as a granular, brittle, white solid.
5. Preparation of Poly(allylamine) hydrochloride Crosslinked with butanedioldiglycidyl ether
To a 5 gallon plastic bucket was added poly(allylamine) hydrochloride prepared as described in Example 3 (500 g) and water (2 L). The mixture was stirred to dissolve the hydrochloride and the pH was adjusted to 10 by adding solid NaOH (134.6 g). The resulting solution was cooled to room temperature in the bucket, after which 1,4-butanedioldiglycidyl ether crosslinking agent (65 mL) was added all at once with stirring. The resulting mixture was stirred gently until it gelled (about 6 minutes). The crosslinking reaction was allowed to proceed for an additional 18 hours at room temperature, after which the polymer gel was removed and dried in a vacuum oven at 75° C. for 24 hours. The dry solid was then ground and sieved to -30 mesh, after which it was suspended in 6 gallons of water and stirred for 1 hour. The solid was then filtered off and the rinse process repeated two more times. The resulting solid was then air dried for 48 hours, followed by drying in a vacuum oven at 50° C. for 24 hours to yield about 415 g of the crosslinked polymer as a white solid.
6. Preparation of Poly(allylamine) hydrochloride Crosslinked with ethanedioldiglycidyl ether
To a 100 mL beaker was added poly(allylamine) hydrochloride prepared as described in Example 3 (10 g) and water (40 mL). The mixture was stirred to dissolve the hydrochloride and the pH was adjusted to 10 by adding solid NaOH. The resulting solution was cooled to room temperature in the beaker, after which 1,2-ethanedioldiglycidyl ether crosslinking agent (2.0 mL) was added all at once with stirring. The resulting mixture was stirred gently until it gelled (about 4 minutes). The crosslinking reaction was allowed to proceed for an additional 18 hours at room temperature, after which the polymer gel was removed and blended in 500 mL of methanol. The solid was then filtered off and suspended in water (500 mL). After stirring for 1 hour, the solid was filtered off and the rinse process repeated. The resulting solid was rinsed twice in isopropanol (400 mL) and then dried in a vacuum oven at 50° C. for 24 hours to yield 8.7 g of the crosslinked polymer as a white solid.
7. Preparation of Poly(allylamine) hydrochloride Crosslinked with dimethylsuccinate
To a 500 mL round bottom flask was added poly(allylamine) hydrochloride prepared as described in Example 3 (10 g), methanol (100 mL), and triethylamine (10 mL). The mixture was stirred and dimethylsuccinate crosslinking agent (1 mL) was added. The solution was heated to reflux and the stirring discontinued after 30 minutes. After 18 hours, the solution was cooled to room temperature, and the solid filtered off and blended in 400 mL of isopropanol. The solid was then filtered off and suspended in water (1 L). After stirring for 1 hour, the solid was filtered off and the rinse process repeated two more times. The solid was then rinsed once in isopropanol (800 mL) and dried in a vacuum oven at 50° C. for 24 hours to yield 5.9 g of the crosslinked polymer as a white solid.
8. Preparation of Poly(ethyleneimine) Crosslinked with acryloyl chloride
Into a 5 L three neck flask equipped with a mechanical stirred, a thermometer, and an addition funnel was added poly(ethyleneimine) (510 g of a 50% aqueous solution, equivalent to 255 g of dry polymer) and isopropanol (2.5 L). Acryloyl chloride crosslinking agent (50 g) was added dropwise through the addition funnel over a 35 minute period while maintaining the temperature below 29° C. The solution was then heated to 60° C. with stirring for 18 hours, after which the solution was cooled and the solid immediately filtered off. The solid was then washed three times by suspending it in water (2 gallons), stirring for 1 hour, and filtering to recover the solid. Next, the solid was rinsed once by suspending it in methanol (2 gallons), stirring for 30 minutes, and filtering to recover the solid. Finally, the solid was rinsed in isopropanol as in Example 7 and dried in a vacuum oven at 50° C. for 18 hours to yield 206 g of the crosslinked polymer as a light orange granular solid.
9. Alkylation of Poly(allylamine) Crosslinked with butanedioldiglydicyl ether with 1-iodooctane alkylating Agent
Poly(allylamine) crosslinked with butanedioldiglycidyl ether prepared as described in Example 5 (5 g) was suspended in methanol (100 mL) and sodium hydroxide (0.2 g) was added. After stirring for 15 minutes, 1-iodooctane (1.92 mL) was added and the mixture stirred at 60° C. for 20 hours. The mixture was then cooled and the solid filtered off. Next, the solid was washed by suspending it in isopropanol (500 mL), after which it was stirred for 1 hour and then collected by filtration. The wash procedure was then repeated twice using aqueous sodium chloride (500 mL of a 1 M solution), twice with water (500 mL), and once with isopropanol (500 mL) before drying in a vacuum oven at 50° C. for 24 hours to yield 4.65 g of alkylated product.
The procedure was repeated using 2.88 mL of 1-iodooctane to yield 4.68 g of alkylated product.
10. Alkylation of Poly(allylamine) Crosslinked with epichlorohydrin with 1-iodooctane alkylating Agent
Poly(allylamine) crosslinked with epichlorohydrin prepared as described in Example 4 (5 g) was alkylated according to the procedure described in Example 9 except that 3.84 mL of 1-iodooctane was used. The procedure yielded 5.94 g of alkylated product.
11. Alkylation of Poly(allylamine) Crosslinked with epichlorohydrin with 1-iodooctadecane alkylating Agent
Poly(allylamine) crosslinked with epichlorohydrin prepared as described in Example 4 (10 g) was suspended in methanol (100 mL) and sodium hydroxide (0.2 g) was added. After stirring for 15 minutes, 1-iodooctadecane (8.1 g) was added and the mixture stirred at 60° C. for 20 hours. The mixture was then cooled and the solid filtered off. Next, the solid was washed by suspending it in isopropanol (500 mL), after which it was stirred for 1 hour and then collected by filtration. The wash procedure was then repeated twice using aqueous sodium chloride (500 mL of a 1 M solution), twice with water (500 mL), and once with isopropanol (500 mL) before drying in a vacuum oven at 50° C. for 24 hours to yield 9.6 g of alkylated product.
12. Alkylation of Poly(allylamine) Crosslinked with butanedioldiglycidyl ether with 1-iodododecane alkylating Agent
Poly(allylamine) crosslinked with butanedioldiglycidyl ether prepared as described in Example 5 (5 g) was alkylated according to the procedure described in Example 11 except that 2.47 mL of 1-iodododecane was used. The procedure yielded 4.7 g of alkylated product.
13. Alkylation of Poly(allylamine) Crosslinked with butanedioldiglycidyl ether with benzyl bromide alkylating Agent
Poly(allylamine) crosslinked with butanedioldiglycidyl ether prepared as described in Example 5 (5 g) was alkylated according to the procedure described in Example 11 except that 2.42 mL of benzyl bromide was used. The procedure yielded 6.4 g of alkylated product.
14. Alkylation of Poly(allylamine) Crosslinked with epichlorohydrin with benzyl bromide alkylating Agent
Poly(allylamine) crosslinked with epichlorohydrin prepared as described in Example 4 (5 g) was alkylated according to the procedure described in Example 11 except that 1.21 mL of benzyl bromide was used. The procedure yielded 6.6 g of alkylated product.
15. Alkylation of Poly(allylamine) Crosslinked with epichlorohydrin with 1-iododecane alkylating Agent
Poly(allylamine) crosslinked with epichlorohydrin prepared as described in Example 4 (20 g) was alkylated according to the procedure described in Example 11 except that 7.15 g of 1-iododecane and 2.1 g of NaOH were used. The procedure yielded 20.67 g of alkylated product.
16. Alkylation of Poly(allylamine) Crosslinked with epichlorohydrin with 1-iodobutane alkylating Agent
Poly(allylamine) crosslinked with epichlorohydrin prepared as described in Example 4 (20 g) was alkylated according to the procedure described in Example 11 except that 22.03 g of 1-iodobutane and 8.0 g of NaOH were used. The procedure yielded 24.0 g of alkylated product.
The procedure was also followed using 29.44 g and 14.72 g of 1-iodobutane to yield 17.0 g and 21.0 g, respectively, of alkylated product.
17. Alkylation of Poly(allylamine) Crosslinked with epichlorohydrin with 1-iodotetradecane alkylating Agent
Poly(allylamine) crosslinked with epichlorohydrin prepared as described in Example 4 (5 g) was alkylated according to the procedure described in Example 11 except that 2.1 mL of 1-iodotetradecane was used. The procedure yielded 5.2 g of alkylated product.
The procedure was also followed using 6.4 mL of 1-iodotetradecane to yield 7.15 g of alkylated product.
18. Alkylation of Poly(allylamine) Crosslinked with epichlorohydrin with 1-iodooctane alkylating Agent
Poly(allylamine) crosslinked with epichlorohydrin prepared as described in Example 8 (5 g) was alkylated according to the procedure described in Example 11 except that 1.92 mL of 1-iodooctane was used. The procedure yielded 5.0 g of alkylated product.
19. Alkylation of a Copolymer of diethylene triamine and epichlorohydrin with 1-iodooctane alkylating Agent
A copolymer of diethylene triamine and epichlorohydrin (10 g) was alkylated according to the procedure described in Example 11 except that 1.92 mL of 1-iodooctane was used. The procedure yielded 5.3 g of alkylated product.
20. Alkylation of Poly(allylamine) Crosslinked with epichlorohydrin with 1-iodododecane and glycidyl-propyltrimethylammonium chloride alkylating Agents
Poly(allylamine) crosslinked with epichlorohydrin prepared as described in Example 4 (20 g) was alkylated according to the procedure described in Example 11 except that 23.66 g of 1-iodododecane, 6.4 g of sodium hydroxide, and 500 mL of methanol were used. 24 grams of the alkylated product was then reacted with 50 g of 90% glycidylpropyltrimethylammonium chloride in methanol (1 L). The mixture was stirred at reflux for 24 hours, after which it was cooled to room temperature and washed successively with water (three times using 2.5 L each time). Vacuum drying afforded 22.4 g of dialkylated product.
Dialkylated products were prepared in an analogous manner by replacing 1-iodododecane with 1-iododecane and 1-iodooctadecane, respectively, followed by alkylation with glycidylpropyltrimethylammonium chloride.
21. Alkylation of Poly(allylamine) Crosslinked with epichlorohydrin with glycidylpropyltrimethylammonium chloride alkylating Agent
Poly(allylamine) crosslinked with epichlorohydrin prepared as described in Example 4 (5 g) was reacted with 11.63 g of 90% glycidylpropyltrimethylammonium chloride (1 mole equiv.) in methanol (100 mL). The mixture was stirred at 60° C. for 20 hours, after which it was cooled to room temperature and washed successively with water (three times using 400 mL each time) and isopropanol (one time using 400 mL). Vacuum drying afforded 6.93 g of alkylated product.
Alkylated products were prepared in an analogous manner using 50%, 200%, and 300% mole equiv of 90% glycidylpropyltrimethylammonium chloride.
22. Alkylation of Poly(allylamine) Crosslinked with epichlorohydrin with (10-bromodecyl)trimethylammonium bromide alkylating Agent
The first step is the preparation of (10-bromodecyl) trimethylammonium bromide as follows. 1, 10-dibromodecane (200 g) was dissolved in methanol (3 L) in a 5 liter three neck round bottom flask fitted with a cold condenser (-5° C.). To this mixture was added aqueous trimethylamine (176 mL of a 24% aqueous solution, w/w). The mixture was stirred at room temperature for 4 hours, after which is was heated to reflux for an additional 18 hours. At the conclusion of the heating period, the flask was cooled to 50° C. and the solvent removed under vacuum to leave a solid mass. Acetone (300 mL) was added and the mixture stirred at 40° C. for 1 hour. The solid was filtered off, resuspended in an additional portion of acetone (1 L), and stirred for 90 minutes.
At the conclusion of the stirring period, the solid was filtered and discarded, and the acetone fractions were combined and evaporated to dryness under vacuum. Hexanes (about 1.5 L) were added and the mixture then stirred for 1 hour, after which the solid was filtered off and then rinsed on the filtration funnel with fresh hexanes. The resulting solid was then dissolved in isopropanol (75 mL) at 40° C. Ethyl acetate (1500 mL) was added and the temperature raised to about 50° C. to fully dissolve all solid material. The flask was then wrapped in towels and placed in a freezer for 24 hours, resulting in the formation of solid crystals. The crystals were filtered off, rinsed in cold ethyl acetate, and dried in a vacuum oven at 75° C. to yield 100.9 g of (10-bromodecyl) trimethyl-ammonium bromide as white crystals.
Poly(allylamine) crosslinked with epichlorohydrin prepared as described in Example 4 (10 g) was suspended in methanol (300 mL). Sodium hydroxide (3.3 g) was added and the mixture stirred until it dissolved. (10-bromodecyl) trimethylammonium bromide (20.7 g) was added and the mixture was refluxed with stirring for 20 hours. The mixture was then cooled to room temperature and washed successively with methanol (two times using 1 L each time), sodium chloride) two times using 1 L of 1 M solution each time), water (three times using 1 L each time), and isopropanol (one time using 1 L). Vacuum drying yielded 14.3 g of alkylated product.
23. Alkylation of Poly(allylamine) Crosslinked with epichlorohydrin with (10-bromodecyl)trimethylammonium bromide and 1,10-dibromodecane alkylating Agents
1,10-dibromodecane (200 g) was dissolved in methanol (3 L) in a 5 liter round bottom flask fitted with a cold condenser (-5° C.). To this mixture was added aqueous trimethylamine (220 mL of a 24% aqueous solution, w/w). The mixture was stirred at room temperature for 4 hours, after which it was heated to reflux for an additional 24 hours. The flask was then cooled to room temperature and found to contain 3350 mL of clear liquid.
Poly(allylamine) crosslinked with epichlorohydrin prepared as described in Example 4 (30 g) was suspended in the clear liquid (2 L) and stirred for 10 minutes. Sodium hydroxide (20 g) was then added and the mixture stirred until it had dissolved. Next, the mixture was refluxed with stirring for 24 hours, cooled to room temperature, and the solid filtered off. The solid was then washed successively with methanol (one time using 10 L), sodium chloride (two times using 10 L of a 1 M solution each time), water (three times using 10 L each time), and isopropanol (one time using 5 L). Vacuum drying afforded 35.3 g of dialkylated product.
24. Alkylation of Poly(allylamine) Crosslinked with epichlorohydrin with (10-bromodecyl)trimethylammonium bromide and 1-bromodecane alkylating Agents
Poly(allylamine) crosslinked with epichlorohydrin prepared as described in Example 4 (10 g) was suspended in methanol (300 mL). Sodium hydroxide (4.99 g) was added and the mixture stirred until it dissolved. (10-bromodecyl) trimethylammonium bromide prepared as described in Example 22 (20.7 g) and 1-bromodecane were added and the mixture was refluxed with stirring for 20 hours. The mixture was then cooled to room temperature and washed successively with methanol (two times using 1 L each time), sodium chloride (two times using 1 L of a 1 M solution each time), water (three times using 1 L each time), and isopropanol (one time using 1 L). Vacuum drying yielded 10.8 g of dialkylated product.
Dialkylated products were also prepared in analogous fashion using different amounts of 1-bromodecane as follows: (a) 3.19 g 1-bromodecane and 4.14 g sodium hydroxide to yield 11.8 g of dialkylated product; (b) 38.4 g 1-bromodecane and 6.96 g sodium hydroxide to yield 19.1 g of dialkylated product.
Dialkylated products were also prepared in analogous fashion using the following combinations of alkylating agents: 1-bromodecane and
(4-bromobutyl)trimethylammonium bromide; 1-bromodecane and
(6-bromohexyl)trimethylammonium bromide; 1-bromodecane and
(8-bromooctyl)trimethylammonium bromide; 1-bromodecane and
(2-bromoethyl)trimethylammonium bromide; 1-bromodecane and
(3-bromopropyl)trimethylammonium bromide; 1-bromohexane and
(6-bromohexyl)trimethylammonium bromide; 1-bromododecane and
(12-bromododecyl)trimethyl-ammonium bromide; and 1-bromooctane and
(6-bromohexyl) trimethylammonium bromide.
25. Alkylation of Poly(allylamine) Crosslinked with epichlorohydrin with 11-bromo-1-undecanol alkylating Agent
Poly(allylamine) crosslinked with epichlorohydrin prepared as described in Example 4(5.35 g) was suspended in methanol (100 mL). Sodium hydroxide (1.10 g) 5 was added and the mixture stirred until it dissolved. 11-bromo-1-undecanol (5.0 g) was added and the mixture was refluxed with stirring for 20 hours, after which it was cooled to room temperature and washed successively with methanol (one time using 3 L), sodium chloride (two times using 500 mL of a 1 M solution each time), and water (three times using 1 L each time). Vacuum drying yielded 6.47 g of alkylated product.
The reaction was also performed using 1.05 g sodium hydroxide and 10 g 11-bromo-1-undecanol to yield 8.86 g of alkylated product.
26. Alkylation of Poly(allylamine) Crosslinked with epichlorohydrin with N-(2,3-epoxypropane)butyramide alkylating Agent
The first step is the preparation of N-allyl butyramide as follows.
Butyroyl chloride (194.7 g, 1.83 mol) in 1 L of tetrahydrofuran was added to a three neck round bottom flask equipped with a thermometer, stir bar, and dropping funnel. The contents of the flask were then cooled to 15° C. in an ice bath while stirring. Allylamine (208.7 g, 3.65 mol) in 50 mL of tetrahydrofuran was then added slowly through the dropping funnel while maintaining stirring. Throughout the addition, the temperature was maintained at 15° C. After addition was complete, stirring continued for an additional 15 minutes, after which the solid allylamine chloride precipitate was filtered off. The filtrate was concentrated under vacuum to yield 236.4 g of N-allyl butyramide as a colorless viscous liquid.
N-allyl butyramide (12.7 g, 0.1 mol) was taken into a 1 L, round bottom flask equipped with a stir bar and air condenser. Methylene chloride (200 mL) was added to the flask, followed by 3-chloroperoxybenzoic acid (50-60% strength, 200 g) in five portions over the course of 30 minutes and the reaction allowed to proceed. After 16 hours, TLC analysis (using 5% methanol in dichloromethane) showed complete formation of product. The reaction mixture was then cooled and filtered to remove solid benzoic acid precipitate. The filtrate was washed with saturated sodium sulfite solution (two times using 100 mL each time) and then with saturated dosium bicarbonate solution (two times using 100 mL each time). The dichloromethane layer was then dried with anhydrous sodium sulfate and concentrated under vacuum to yield 10.0 g of N-(2,3-epoxypropane) butyramide as a light yellow viscous liquid.
Poly(allylamine) crosslinked with epichlorohydrin prepared as described in Example 4 (10 g, -80 sieved) and methanol (250 mL) were added to a 1 L round bottom flask, followed by N-(2,3-epoxypropane) butyramide (0.97 g, 0.0067 mol, 5 mol %) and then sodium hydroxide pellets (0.55 g, 0.01375 mol). The mixture was stirred overnight at room temperature. After 16 hours, the reaction mixture was filtered and the solid washed successively with methanol (three times using 300 mL each time), water (two times using 300 mL each time), and isopropanol (three times using 300 mL each time. Vacuum drying at 54° C. overnight yielded 9.0 g of the alkylated product as a light yellow powder.
Alkylated products based upon 10 mol %, 20 mol %, and 30 mol % N-(2, 3-epoxypropane) butyramide were prepared in analogous fashion except that (a) in the 10 mol % case, 1.93 g (0.013 mol) N-(2,3-epoxypropane) butyramide and 1.1 g (0.0275 mol) sodium hydroxide pellets were used to yield 8.3 g of alkylated product, (b) in the 20 mol % case, 3.86 g (0.026 mol) N-(2,3-epoxypropane) butyramide and 2.1 g (0.053 mol) sodium hydroxide pellets were used to yield 8.2 g of alkylated product, and (c) in the 30 mol % case, 5.72 g (0.04 mol) N-(2,3-epoxypropane) butyramide and 2.1 g (0.053 mol) sodium hydroxide pellets were used to yield 8.32 g of alkylated product.
27. Alkylation of Poly(allylamine) Crosslinked with epichlorohydrin with N-(2,3-epoxypropane) hexanamide alkylating Agent
The first step is the preparation of N-allyl hexanamide as follows.
Hexanoyl chloride (33 g, 0.25 mol) in 250 mL of tetrahydrofuran was added to a three neck round bottom flask equipped with a thermometer, stir bar, and dropping funnel. The contents of the flask were then cooled to 15° C. in an ice bath while stirring. Allylamine (28.6 g, 0.5 mol) in 200 mL of tetrahydrofuran was then added slowly through the dropping funnel while maintaining stirring. Throughout the addition, the temperature was maintained at 15° C. After addition was complete, stirring continued for an additional 15 minutes, after which the solid allylamine chloride precipitate was filtered off. The filtration was concentrated under vacuum to yield 37 g of N-allyl hexanamide as a colorless viscous liquid.
N-allyl hexanamide (16 g, 0.1 mol) was taken into a 1 L round bottom flask equipped with a stir bar and air condenser. Methylene chloride (200 mL) was added to the flask, followed by 3-chloroperoxybenzoic acid (50-60% strength, 200 g) in five portions over the course of 30 minutes and the reaction allowed to proceed. After 16 hours, TLC analysis (using 5% methanol in dichloromethane) showed complete formation of product. The reaction mixture was then cooled and filtered to remove solid enzoic acid precipitate. The filtrate was washed with saturated sodium sulfite solution (two times using 100 mL each time) and then with saturated sodium bicarbonate solution (two times using 100 mL each time). The dichloromethane layer was then dried with anhydrous sodium sulfate and concentrated under vacuum to yield 14.2 g of N-(2,3-epoxypropane) hexanamide as a light yellow viscous liquid.
Poly(allylamine) crosslinked with epichlorohydrin prepared as described in Example 4 (10 g, -80 sieved) and methanol (250 mL) were added to a 1 L round bottom flask, followed by N-(2,3-epoxypropane) hexanamide (4.46 g, 0.026 mol, 20 mol %) and then sodium hydroxide pellets (2.1 g, 0.053 mol). The mixture was stirred overnight at room temperature. After 16 hours, the reaction mixture was filtered and the solid washed successively with methanol (three times using 300 mL each time), water (two times using 300 mL each time), and isopropanol (three times using 300 mL each time. Vacuum drying at 54° C. overnight yielded 9.59 g of the alkylated product as a light yellow powder.
An alkylated product based upon 30 mol % N-(2,3-epoxypropane) hexanamide was prepared in analogous fashion except that 6.84 g (0.04 mol) N-(2,3-epoxypropane) hexanamide was used to yield 9.83 g of alkylated product.
28. Alkylation of Poly(allylamine) Crosslinked with epichlorohydrin with (6-Bromohexyl)trimethylammonium bromide and 1-bromodecane alkylating Agent
To a 12-1 round bottom flask equipped with a mechanical stirrer, a thermometer, and a condenser is added methanol (5 L) and sodium hydroxide (133.7 g). The mixture is stirred until the solid has dissolved and crosslinked poly(allylamine) (297 g; ground to -80 mesh size) is added along with additional methanol (3 L). (6-Bromohexyl) trimethylammonium bromide (522.1 g) and 1-bromodecane (311.7 g) are added and the mixture heated to 65° C. with stirring. After 18 hours at 65° C. the mixture is allowed to cool to room temperature. The solid is filtered off and rinsed by suspending, stirring for 30 minutes, and filtering off the solid from: methanol, 12 L; methanol, 12L; 2 M aqueous NaCl, 22 L; 2 M aqueous NaCl, 22 L; deionized water, 22 L; deionized water, 22 L; deionized water, 22 L and isopropanol, 22 L. The solid is dried in a vacuum oven at 50° C. to yield 505.1 g of off-white solid. the solid is then ground to pass through an 80 mesh sieve.
Testing of Polymers
Preparation of Artificial Intestinal Fluid
Sodium carbonate (1.27 g) and sodium chloride (1.87 g) were dissolved in 400 ml of distilled water. To this solution was added either glycocholic acid (1.95 g, 4.0 mmol) or glycochenodeoxycholic acid (1.89 g, 4.0 mmol) to make a 10 mM solution. The pH of the solution was adjusted to 6.8 with acetic acid. These solutions were used for the testing of the various polymers.
Polymers were tested as follows.
To a 14 mL centrifuge tube was added 10 mg of polymer and 10 mL of a bile salt solution in concentrations ranging from 0.1-10 mM prepared from 10 mM stock solution (prepared as previously described) and buffer without bile salt, in the appropriate amount. The mixture was stirred in a water bath maintained at 37° C. for three hours. The mixture was then filtered. The filtrate was analyzed for total 3-hydroxy steroid content by an enzymatic assay using 3a-hydroxy steroid dehydrogenase, as described below.
Enzymatic Assay for Total Bile Salt Content
Four stock solutions were prepared.
Solution 1--Tris-HCl buffer, containing 0.133 M Tris, 0.666 mM EDTA at pH 9.5.
Solution 2--Hydrazine hydrate solution, containing 1 M hydrazine hydrate at pH 9.5.
Solution 3--NAD solution, containing 7 mM NAD+ at pH 7.0.
Solution 4--HSD solution, containing 2 units/mL in Tris-HCl buffer (0.03 M Tris, 1 mM EDTA) at pH 7.2.
To a 3 mL cuvette was added 1.5 mL of Solution 1, 1.0 mL of Solution 2, 0.3 mL of solution 3, 0.1 mL of Solution 4 and 0.1 mL of supernatant/filtrate from a polymer test as described above. The solution was placed in a UV-VIS spectrophotometer and the absorbance (O.D.) of NADH at 350 nm was measured. The bile salt concentration was determined from a calibration curve prepared from dilutions of the artificial intestinal fluid prepared as described above.
All of the polymers previously described were tested in the above manner and all were efficacious in removing bile salts from the artificial intestinal fluid.
Use
The polymers according to the invention may be administered orally to a patient in a dosage of about 1 mg/kg/day to about 10 g/kg/day; the particular dosage will depend on the individual patient (e.g., the patient's weight and the extent of bile salt removal required). The polymer may be administrated either in hydrated or dehydrated form, and may be flavored or added to a food or drink, if desired to enhance patient acceptability. Additional ingredients such as other bile acid sequestrants, drugs for treating hypercholesterolemia, atherosclerosis or other related indications, or inert ingredients, such as artificial coloring agents may be added as well.
Examples of suitable forms for administration include pills, tablets, capsules, and powders (e.g., for sprinkling on food ). The pill, tablet, capsule, or powder can be coated with a substance capable of protecting the composition from the gastric acid in the patient's stomach for a period of time sufficient to allow the composition to pass undisintegrated into the patient's small intestine. The polymer may be administered alone or in combination with a pharmaceutically acceptable carrier substance, e.g., magnesium carbonate, lactose, or a phospholipid with which the polymer can form a micelle.
While this invention has been particularly shown and described with references to preferred 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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The invention relates to a method for removing bile salts from a patient in need thereof and compositions useful in the method. The method comprises administering to the patient a therapeutically effective amount of an alkylated and crosslinked polymer. The alkylated and crosslinked polymer comprises the reaction product of polymers, or salts and copolymers thereof having amine containing repeat units, with at least one aliphatic alkylating agent and a crosslinking agent.
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CROSS-REFERENCE TO RELATED PATENT APPLICATION
[0001] This application claims priority as a divisional of U.S. patent application Ser. No. 11/002,611, filed on Dec. 2, 2004 and entitled “Methods and Apparatus for Making Diamond-Like Carbon Films” by Fu-Jann Pem et al., hereby incorporated by reference as if fully set forth herein.
CONTRACTUAL ORIGIN OF INVENTION
[0002] The United States Government has rights in this invention pursuant to Contract No. DEAC36-99GO10337 between the U.S. Department of Energy and the National Renewable Energy Laboratory, a Division of Midwest Research Institute.
FIELD OF THE INVENTION
[0003] The present invention relates to deposition of diamond-like carbon films, and more specifically to ion-assisted plasma-enhanced deposition of diamond-like carbon films for uses including protection of materials against exposure to harmful agents, for example, encapsulation of surface of films, such as photovoltaic solar cells for protection against chemical, mechanical, and radiation damage.
BACKGROUND OF THE INFORMATION
[0004] A method of this type is described in Armenian patent (AM N851, HO1L31/02). According to this patent the deposition of diamond-like carbon (DLC) film on the front surface of a silicon photovoltaic cell with p-n junction and two contacts is performed using plasma flow produced by an ion source comprising a cylindrical hollow cathode, anode and a magnet (solenoid). The method is simple and reliable. Its disadvantage is in a considerable degree of non-uniformity of density of plasma flow and ion energy which limits the area of uniformly of DLC encapsulated substrates by 20 cm 2 .
[0005] A method is known of deposition of antireflecting and passivating diamond-like or composite diamond film on the surface of optoelectronic devices (solar cells or photodetectors) using high-frequency plasma (Patent CN N1188160, C23C16/26, G02B1/11, 1998).
[0006] The closest to the claimed invention is a method of coating of substrates with various films including DLC using the separation of the substrate voltage from the production of the plasma (Patent H5 N6372303, C23C016/26, 2002). The substrate, biased by a combination of a direct voltage and a pulsed voltage with a frequency of 0.1 kHz-10 MHz, is rotated about several axes of rotation in a vacuum chamber with various plasma sources. The method produces a multilayer structure that is wear-resistant and that reduces friction. Optical characteristics of the coating are not controlled. It is not possible to produce by this method of DLC coating on plain substrates of large area.
SUMMARY OF THE INVENTION
[0007] An object of the present invention is to provide a method scaled upwards, which facilitates deposition of uniform (with degree of non-uniformity of optical parameters less than 5%) DLC film on large area surface (e.g., more than 110 cm 2 ) photovoltaic solar cells to produces a DLC film that has optical parameters varied within the given range and that possesses stability against harmful effects of the environment.
[0008] The object is achieved by the control of ion energy, plasma discharge current and spatial distribution of ion current density by an electric field produced by a system of annular electrodes, comprising diaphragm, neutralizer, and accelerating electrodes. The uniformity of plasma is monitored by measurement of ion current density at the surface of the substrate (photovoltaic solar cell).
[0009] According to the present invention, DLC films with refractive index in the range of 1.48-2.60 are obtained by varying ion energy in the range of 20-140 eV, plasma current density in the range of 0.2-0.8 mA·cm −2 , and hydrocarbon content in the feed gas mixture in the range of 2-40%. Rotation of the substrates about three axes is used to improve the uniformity of DLC films, which allows the substrate temperature not to exceed 80° C.
[0010] According to the present invention, DLC films can be manufactured in the form of monolayer or multilayer (with discrete changes of refractive index) structures, or in the form of a layer with the refractive index continuously varying along the depth of film thickness. Used as encapsulants for photovoltaic solar cells, they allow light transmission of at least 95% and reflectivity of 5% within the range of photosensitivity of silicon. These encapsulants possess stability against UV, proton, and electron irradiation, chemical stability against attacks by strong acids, thermal and weathering stability against high temperature and humidity, and mechanical stability against scratching and environmental elements.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 shows a cross-sectional view of an ion source and a system of electrodes to control plasma.
[0012] FIG. 2 shows spatial distribution of ion current density without (curve 1 ) and with (curve 2 ) a system of electrodes.
[0013] FIG. 3 shows a side view of a device for rotation of substrates.
[0014] FIG. 4 shows a top view of the device shown in FIG. 3 .
[0015] FIG. 5 shows a side view of the device shown in FIG. 3 in combination with the system of electrodes shown in FIG. 1 .
[0016] FIG. 6 shows a Raman spectra of three DLC films.
[0017] FIG. 7 shows reflection spectra from indicated spots of a DLC film deposited on a Si substrate.
[0018] FIG. 8 shows transmission spectra of three DLC films deposited on sapphire substrates under various conditions.
[0019] FIG. 9 shows a cross section of a photovoltaic cell with contact grid and bi-layer DLC film encapsulant.
[0020] FIG. 10 shows reflectance spectrum of a bi-layer DLC film sample on c-Si substrate with film parameters of n 1 =2.4, d 1 =60 nm, and n 2 =1.6, and d 2 =80 nm.
[0021] FIG. 11 shows a spectral response of a silicon photovoltaic cell (excited from the back).
[0022] FIG. 12 shows the effect of proton irradiation on spectral efficiency of DLC coated photovoltaic cells.
DETAILED DESCRIPTION
[0023] FIG. 1 shows an apparatus that can be used for carrying out the method of depositing diamond-like carbon (DLC) films according to this invention. It includes a vacuum chamber 4 , in which a radial direct current ion source is provided by an anode 1 , a cylindrical cathode 2 and a magnet (solenoid) 3 . A direct voltage potential in a range of 1-4 kV is applied between cathode 2 and anode 1 . The magnet 3 forms magnetic field perpendicular to the electric field. Plasma 16 is formed in a gap between anode 1 and cathode 2 and is shaped in the form of a truncated cone as it projects into the chamber 4 . Grounded diaphragm 5 slows down electrons and cuts off ions which move at angles more than 40° relative to the plasma axis to condition and collimate a flow of the ions toward the substrate 9 . A neutralizer electrode 6 , is placed outside the magnetic field. An alternating (AC) voltage in a range of 30-50 V is applied to the neutralizer electrode 6 in order to create the alternating current (AC) for providing the electron flow due to a thermo emission phenomenon. Since the anode voltage is about +2.5 kV, the potential of the neutralizer is negative relative to the anode. Therefore, the flow of emitted electrons in the plasma region is provided to neutralize slow ions and non-dissociated radicals (C X H y ). As a consequence the ion flow reaching an accelerating electrode 7 possesses a low degree of non-uniformity of energies, i.e., fairly uniform ion energy. The accelerating electrode 7 provided with a grid 8 enables one to control or correct the energy of ions reaching the surface of a substrate (photovoltaic cell) 9 mounted on a support device 10 . A voltage supply (not shown) biases accelerating electrode 7 and the support device 10 in a voltage range of −50 to −400 V, which provides average ion energy within the range 20 to 150 eV.
[0024] Initial (that is without the use of the electrodes 5 , 6 , 7 ) spatial distribution of ion current density I is approximated by the Boltzman function ( FIG. 2 , curve 21 ) with a 10% degree of non-uniformity only within a limited area of about 20 cm 2 . Introduction of the electrodes 5 , 6 and 7 produces much better plasma uniformity. Plasma is now shaped in the form of a cylinder, so that a 10% degree of non-uniformity of ion current density is measured within a diameter of about 12.6 cm ( FIG. 2 , curve 22 ). The degree of non-uniformity of energy of ions C + , H + , N + and Ar + does not exceed 10%. The apparatus and method of this invention can also be scaled up to larger deposition areas than the 12-13 cm diameter of this example and still achieve this uniformity in ion energy over such layer. Proportion of concentration of these ions is controlled by feed gas mixture composition (C 7 H 8 , Ar, N 2 ) brought into chamber 4 via a gas inlet conduit through the anode 1 . The effluent gases leave through an exhaust system 11 .
[0025] In a preferred deposition apparatus embodiment 100 illustrated in FIGS. 3-5 , a plurality of support devices 10 are configured and motivated to move a plurality of substrates 9 (see FIG. 1 ; not shown in FIGS. 3-5 ) sequentially into and out of alignment with the ion flow 17 . In the apparatus 100 , the individual support devices 10 and substrates 9 are also rotated to expose the substrates 9 to different portions of the ion flow 17 to attain uniform deposition of material on the substrates 9 .
[0026] As illustrated in FIGS. 3-5 , the support devices 10 of the apparatus 100 are ganged or grouped into a plurality of gangs 102 , 104 , 106 , 108 . Each gang 102 , 104 , 106 , 108 has at least one support device 10 (four support devices 10 in the example of FIGS. 3-5 ). The support devices 10 are motivated to rotate about their respective axes 110 , as indicated by arrows 111 in FIG. 3 . The gangs 102 , 104 , 106 , 108 are mounted on respective struts 13 , which extend radially outward from a main shaft 12 . The main shaft 12 rotates, as indicated by arrow 120 , to move the respective gangs 102 , 104 , 106 , 108 into and out of alignment with the ion flow 17 so that the substrates 9 in the respective gangs 102 , 104 , 106 , 108 are exposed to the ion flow 17 . This rotation of the gangs about the axis of shaft 12 into and out of alignment with the ion flow 17 not only enables the individual substrates 9 to get exposed to more portions of the ion flow 17 and thereby avoid uneven deposition, but also so that they are exposed to the ion flow 17 for limited times and then rotated out of such alignment for a time to avoid unnecessary heat build-up and temperature rise in the substrate 9 . As the substrates 9 on one gang rotate out alignment with the ion flow 17 , they can cool while other substrates 9 are rotated into alignment to receive the ion flow 17 and the resulting deposition. At the same time, the support devices 10 rotate the substrates 9 about their respective axes 110 , as indicated by arrows 111 , to also help achieve uniform deposition on the substrates 9 .
[0027] To further enhance uniform deposition, each gang 102 , 104 , 106 , 108 can be rotated about the axis of its respective strut 13 , as indicated by arrow 130 in FIGS. 3 and 5 . For example, as shown in FIGS. 3-5 , the four support devices 10 on each gang 102 , 104 , 106 , 108 are mounted on the distal ends of four arms 131 extending radially outward from a hub 132 of a wheel 14 . The hub 132 is rotatable with respect to the axis of the strut 13 on which it is mounted so that the wheel 14 rotates the support devices 10 and substrates 9 about the respective axes of struts 13 , as indicated by arrow 130 .
[0028] While no particular orientation is essential, the shaft 12 is vertical in the example of FIGS. 3-5 , so the axis of struts 13 and mountings 110 are horizontal. Therefore, in this example, rotation about a main vertical axis 12 is combined with rotation of four wheels 14 about the four horizontal axes of struts 13 . Support devices 10 mounted on the wheels 14 rotate about their respective horizontal axes 110 . As a consequence, substrates 9 perform complex movement about the base 15 . Rotation in the range 10-30 rpm provides optimal trajectory which drives the substrates to traverse all the zones or areas across the plasma flow 17 and spend some time outside it, which facilitates their cooling. The complex movement of substrates 9 provides for better uniformity of the DLC coating (with less than 5% variation in mechanical and optical parameters—sometimes called “spread”—within an area of ˜110 cm 2 ) and relatively low (30-80° C.) temperature of deposition. The circular area of about 125 cm 2 (diameter of about 12.6 cm) in the example of the FIG. 2 analysis exceeds the area of the silicon plate and correspondingly provides the uniformity or homogeneity of the deposited coating. As mentioned above, the method and apparatus of this invention can be scaled up to larger deposition areas than the examples described herein and still achieve this uniformity in mechanical and optical parameters for such larger deposition areas. Therefore, this invention is not limited to the example areas of the examples provided herein.
[0029] A film manufactured according to the present invention is high quality diamond-like material. FIG. 6 shows a Raman spectra of the DLC films of various thickness (240, 540, and 840 nm, for curves 61 , 62 and 63 respectively) deposited under various technological conditions. The position of maximum of the curves indicates predominance of sp 3 bonds in these films.
[0030] Improved film uniformity obtained according to the present invention is illustrated in FIG. 7 , which shows the nearly identical reflectance spectra for the different areas (as indicated) of a 12-cm diameter DLC film.
[0031] Properties of DLC films, in particular their optical parameters can be tuned by exact control of plasma parameters (ion beam current and energy; feed gas mixture composition). Table 1 shows parameters of 60-900 nm thick DLC films manufactured under various technological conditions where U ac is anode 1 to cathode 2 voltage, I ac is plasma discharge current in the ion source, U b is the bias applied to the diaphragm 7 and the support device 10 , <E k > is the average kinetic energy of ions reaching the surface of the substrate (photovoltaic cell) 9 , I p is the plasma current density at the surface of the substrate 9 , n is the refractive index of a DLC film, H V is its microhardness. The feed gas mixture (C 7 H 8 , Ar, N 2 ) was 55% Ar, with 45% left for C 7 H 8 and N 2 . This method and apparatus also works with other carrier gases besides N 2 and Ar, as will be understood by persons skilled in the art. In Table 1, the percentage of C 7 H 8 is given.
[0000]
TABLE 1
C 7 H 8/
U ac ,
I ac /
U b/
<E k/
I p/
HV
%
KV
mA
V
eV
mA/cm 2
n
kg/mm 2
35
2.5
30
−300
90
0.20
1.48
2500
28
2.6
35
−350
100
0.25
2.00
2750
24
2.8
40
−400
140
0.30
2.10
2700
18
2.2
80
−250
60
0.60
2.40
3000
12
2.3
100
−300
65
0.65
2.45
2950
15
2.4
120
−350
80
0.80
2.35
3100
10
1.5
45
−20
20
0.35
2.55
2900
8
1.8
50
−50
25
0.40
2.60
2850
4
2.0
60
−100
50
0.45
2.57
2800
[0032] It is seen that with proper choice of deposition condition, the DLC films are manufactured with various microhardness (2500-3100 kg·mm −2 ) and refractive indexes (1.48-2.60). The films show a density varying in the range of 1.8-2.35 g·cm −3 and are characterized by small amount of microdefects, low internal stresses, good adhesion and reduced friction. These properties grant high mechanical stability of the DLC encapsulants.
[0033] DLC films with low refractive indexes are manufactured at the ratio C 7 H 8 :N 2 =40:5 and at the average ion energy less than 140 eV. A feed gas mixture with higher ratio C 7 H 8 :N 2 produces DLC films with unacceptable high optical absorption. Ions with energies higher than 140 eV cause degradation of the properties of photovoltaic cells. Films manufactured at ion energies of less than 20 eV possess too high refractive index to be useful for antireflective coating. Plasma current less than 0.20 mA·cm −2 does not grant proper efficiency of the DLC deposition. Plasma current more then 0 . 80 mA·cm −2 causes increase an amount of defects in the films.
[0034] Optical transmission of DLC coating and, consequently, efficiency improvement of photovoltaic solar cells can be tuned by exact control of deposition conditions. FIG. 8 shows the transmittance spectra of two DLC film samples of the same thickness (curves 81 and 82 ), but deposited on sapphire substrates under different conditions. Transmittance is determined as T=I/I 0 (1−R), where I 0 and I are the incident and transmitted light intensities, respectively, and R is the reflectance of a film. It is seen that the transmission of the two films differ by 17% at λ=260 nm. In the range of 300-620 nm, transmittance of one of the 185 nm thick films is ˜98% with a band gap of ˜4 eV; this grants very low absorption losses which is a prerequisite of effective use of such films as encapsulants for photovoltaic solar cells. Curve 83 of FIG. 8 corresponds to a 240 nm film sample deposited under technological conditions different from those for the other two samples.
[0035] Based upon the relationship between the technological parameters and value of refractive index, it is possible to manufacture DLC films with the preset variation of refractive index within the DLC layer that is either multilayer structures or a monolayer with continuous variation of refractive index through the depth of the DLC film thickness.
[0036] As an example, FIG. 9 shows a cross section of a PV cell with a contact grid and bilayer DLC film encapsulant (DLC (1) :n 1 =2.4, d 1 =60 nm; DLC (2) :n 2 =1.6, d 2 =80 nm). FIG. 10 shows the reflection spectrum of the bi-layer DLC structure; the low reflectance (R≦5%) grants good antireflection effects of this PV cell encapsulation.
[0037] FIG. 11 shows a spectral response of a Si PV cell (excited from the back): curve 91 —before DLC coating, curve 92 after DLC coating. The cell efficiency enhancement is stronger than that can be explained by the antireflecting effect. Significant performance improvement is attributed to reduced (surface) boundary recombination losses.
[0038] Weathering and chemical stability tests were performed on DLC encapsulated PV cells. In the course of weathering stability tests, silicon PV cells were kept in a special enclosure (or chamber) at 80-90° C. and relative humidity 90% for 20 hours. Optical and mechanical parameters of DLC films as well as efficiency of DLC coated PV cells were measured before and after the exposure to humid atmosphere. Practically no changes of these parameters were found (the data for PV cells efficiency are presented in Table 2).
[0039] In the course of chemical stability tests the DLC coated silicon PV cells were exposed to one of the following agents:
[0040] concentrated HNO 3 acid, 30 minutes, 25° C.
[0041] diluted (1%) HNO 3 acid, 1 hour, 25° C.
[0042] concentrated H 2 SO 4 acid, 30 minutes, 25° C.
[0043] diluted (1%) H 2 SO 4 acid, 1 hour, 25° C.
[0044] saturated solution of NaCl (sea fog simulation), 40 hours, 25-30° C.
[0045] Similar to weathering stability tests, measurements of reflectivity of DLC coating and PV cell efficiency as well as microscopic inspection of DLC coating surface were performed before and after the exposures. Again no effects of these exposures on the mentioned parameters were found (Table 2). These results demonstrate good chemical stability of DLC coating and are in striking contrast to the data of similar tests performed on ZnS coated silicon PV cells. In the latter case, the ZnS coating was damaged or destroyed and PV cells efficiency decreased by 30%.
[0046] A longer-term stability study was conducted for the DLC-coated Si samples in a stringent damp heat test (85° C./85% RH), which is being used to qualify thin film modules by the PV industry, for 762 hours. Results from the reflectance measurements indicate that the DLC-on-Si thin films show negligible or no change. Additionally, both microhardness and reflectivity did not change after heating at 350° C. for 2 hours, a slight change in reflectivity but not in microhardness was observed if heated at 380° C. for 2 hours. Intense oxidative degradation of the films was observed however, when heated to 410° C. or higher for less than 1 hour.
[0000]
TABLE 2
Efficiency, %
Weathering
Chemical
test
stability test
<Ek>/,
C 7 H 8 /
Si + DLC
Si + DLC
Si + DLC
eV
%
d, nm
PV cell
PV cell
PV cell
55
22
80
9.87
9.85
9.78
70
16
80
9.71
9.75
9.58
65
13
75
8.90
8.93
8.78
60
12
85
9.27
9.23
9.28
75
10
85
9.11
9.18
9.14
65
14
80
8.82
8.90
8.80
[0047] It was found that UV, proton and electron irradiation do not affect the properties of DLC films and DLC encapsulated PV cells. For UV irradiation tests, a high-pressure xenon lamp was used with the spectra similar to that of the sun but with higher intensity of UV. Silicon PV cells with various coatings (DLC, ZnS, SiO 2 ) were exposed to the light of the Xe lamp with a UV power density of ˜0.5 W·cm −2 for ˜400 hours. No effects on the DLC coated PV cell efficiency were found. On the other hand, for a ZnS coated cell a ˜15% decrease of efficiency was observed, possibly due to UV induced degradation of the film transparency and enhancement of the surface recombination rate at the Si-ZnS boundary.
[0048] Proton irradiation is an important factor causing degradation of PV cells used in space. The proton energy interval, which is of interest as far as the effects on the DLC films with technologically realistic thickness (˜2 μm) are concerned, ranges from 10 keV to 500 keV. To choose the conditions of a proton irradiation test, data on the proton spectrum given by the accepted models (such as NASA AP-8 and JPL-91) were used. To simulate the effects of solar proton irradiation, the range of 10-500 keV was divided into two intervals: 10-50 keV and 50-500 keV. Integration of the proton spectrum given by AP-8 model within these intervals for 11 years period gives the fluences 2×10 12 and 5×10 11 cm −2 respectively. To simulate the effect of proton irradiation with the energy in these intervals proton implantation with energies 20 and 150 keV and fluences 10 14 cm −2 and 10 13 cm −2 respectively was used, which allows for all possible errors in proton flux estimates and may correspond to at least 100 years exposure. The implantation was performed into a 1.5 μm DLC film deposited on a quartz substrate and into DLC coatings on two silicon PV cells. No effect of the implantation on the optical properties of DLC film was found. Similarly, the spectral efficiency of the cells was not affected by the implantation ( FIG. 12 ). This means that DLC coating with the thickness ˜2 μm is stable and can serve as a radiation shield against solar protons. Similar results were obtained with 1 MeV electron irradiation.
[0049] The foregoing description of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form or structure disclosed, and other modifications and variations may be possible in light of the above teachings and within the scope of the claims appended hereto. The embodiments described above were chosen and described in order to best explain the principles of the invention and its practical application to thereby enable others skilled in the art to best utilize the invention in various embodiments and various modifications as are suited to the particular use contemplated. It is intended that the appended claims be construed to include other alternative embodiments of the invention except insofar as limited by the prior art. The words “comprise,” “comprising,” “include,” “including,” and “includes” when used in this specification and in the following claims are intended to specify the presence of stated features, integers, components, or steps, but they do not preclude the presence or addition of one or more other features, integers, components, steps or groups thereof.
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Ion-assisted plasma enhanced deposition of diamond-like carbon (DLC) films on the surface of photovoltaic solar cells is accomplished with a method and apparatus for controlling ion energy. The quality of DLC layers is fine-tuned by a properly biased system of special electrodes and by exact control of the feed gas mixture compositions. Uniform (with degree of non-uniformity of optical parameters less than 5%) large area (more than 110 cm 2 ) DLC films with optical parameters varied within the given range and with stability against harmful effects of the environment are achieved.
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This is a continuation of application Ser. No. 07/704,238, filed May 22, 1991, abandoned.
BACKGROUND AND MATERIAL DISCLOSURE STATEMENT
The present invention relates to a xerographic recording apparatus for line-by-line exposure of the surface of a moving photoreceptor and, more particularly, to a circuit for minimizing registration errors in the sagital (slow scan) direction.
Image print bars used in xerographic recording systems are well known in the art. The print bar generally consists of a linear array of a plurality of discrete light emitting sources. Light emitting diode (LED) arrays are preferred for many recording applications. In order to achieve high resolution, a large number of light emitting diodes, or pixels, are arranged in a linear array and means are included for providing a relative movement between the linear array and the photoreceptor so as to produce a scanning movement of the linear array over the surface of the photoreceptor. Thus, the photoreceptor may be exposed to provide a desired image one line at a time as the LED array is advanced relative to the photoreceptor either continuously or in a stepping motion. Each LED in the linear array is used to expose a corresponding pixel in the photoreceptor to a value determined by image defining video data information.
For a print bar with a resolution of 300 sports per inch (300spi), a pixel size of 50×50 microns on 84.67 micron centers would be a typical configuration. In a xerographic application, where an 8.5 inch wide informational line is to be exposed, a linear array of approximately 2250 pixels, arrayed in a single row, would be required. (If two or more rows of parallel staggered rows of LEDs are used, the spacing between adjacent LEDs can be relaxed but the cost then increases.). One problem with prior art print bars is the difficulty of aligning all of the LED pixels in both the linear direction of the array and in the sagital plane, the sagital plane corresponding to the slow scan or process direction of motion of the photoreceptor. Present chip technology enables very accurate pixel placement in the linear direction, but individual pixels, or, more commonly, groups of pixels formed on the same chip, may be misaligned in the sagital direction, resulting in registration errors in later printed copies of the image being recorded. The significance of this type of registration error is amplified when a plurality of image bars are used, for example, in a full color printing system requiring accurate registration of simultaneous line exposures for each color.
It is known in the prior art to align LEDs in multiple rows in both the linear and sagital direction. U.S. Pat. Nos. 4,571,602 and 4,575,739, both to De Schamphelaere et al., disclose a method for correcting registration errors in an image projected onto the surface of a photoreceptor that results from unevenly positioned point sources along an LED array. In operation, driver control circuits 34 and 35 control the energization of individual LEDs located along first and second LED arrays 24 and 25, respectively. Delay registers in control circuit 34 delay the energization of individual LEDs in the first LED array relative to a photoreceptor speed signal and the energization of LEDs along the second LED array. This energization delay aligns each line of the image in the transverse direction.
U.S. Pat. No. 4,525,729 to Agulnek et al. discloses a method for simultaneously controlling at selected different time intervals the energization of individual LEDs within an LED array.
It is not disclosed in the known prior art how to identify individual pixels, or subarrays of pixels within a larger array, which are misaligned with respect to the other pixels and to correct for the misalignment or misregistration. According to the present invention, a circuit and method is provided for first initially calibrating a print bar to identify pixel to pixel mis-registration and then to provide appropriate circuitry for delaying drive signals which are sent to these misregistered pixels to delay their energization to insure that they are registered with the remainder of those LEDs which are in proper registration. More particularly, the present invention relates to an imaging apparatus for line-by-line exposure of the surface of a moving photoreceptor in a slow scan process direction by at least one linear print bar having a multiplicity of light emitting elements, at least some of said elements misregistered in the slow scan direction, the apparatus comprising: driver circuits for energizing said light emitting elements, circuit means for serially applying input data signal to said driver circuits during a line information time period, and
enabling circuit means for applying selectively delayed enabling signals to said drive circuit associated with a light emitting element, or group of light emitting elements, to be energized during the line information time so that the exposed line created by said light emitting elements is in linear registration.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic block diagram of an imaging system incorporating the pixel registration correction circuitry of the present invention.
FIG. 2 shows the linear print bar of FIG. 1 with pixel groups misaligned in the sagital dimension.
FIG. 3 shows a selected group of pixels with one pixel out of registration.
FIG. 4 shows a timing chart for a 16 pixel segment of the image bar of FIG. 1.
FIG. 5 shows a timing chart for the segment of FIG. 4 with one pixel out of registration.
FIG. 6 shows a raster output scanning (ROS) system forming an image in conjunction with a plurality of image bars.
FIG. 7 shows the exposed scan line produced by the ROS system of FIG. 6.
DESCRIPTION OF THE INVENTION
Referring now to FIG. 1, there is shown an image recording system wherein a linear print bar 10, comprising a plurality of LEDS 12 (FIG. 2) aligned in a linear direction in a single row, is positioned above the surface 14 of a photoreceptor web 16 moving in a slow scan process direction indicated by arrow 17. The web surface 14 has been charged to a predetermined potential as is known in the art. The individual LEDs are selectively energized in a manner to be described below to expose the charged surface 14 in conformance with image video data signals generated by a video data source 18. The areas of the web that are exposed are discharged whereas the unexposed areas retain their original charge. The latent image thus formed can then be developed, and the developed image transferred to an output media such as paper and fused. All of these xerographic process steps are well known in the art.
Referring still to FIG. 1, an Electronic Sub System ESS Controller 30 is shown which contains the logic and storage elements for controlling energization of the LEDs comprising print bar 10, via LED driver circuit 31. Incorporated within Controller 30 are a crystal clock 32 and a delay memory storage circuit 34. Driver circuit 31 incorporates a shift register 42, latch register 44 and drive circuit 46. In operation, binary video data signals from data source 18 are read into shift register 42 under control of clocking signals generated by crystal clock 32. Upon receipt of the last binary bit to be entered, the data bits are shifted in parallel into latch register 44 by a latch signal where they are temporarily stored. These signals are shifted out, again in parallel, to driver circuit 46 upon receipt of a latch signal generated by detection of an end of line condition. The driver circuit comprises a plurality of drive transistors, each transistor associated with an individual LED or an LED grouping. The drive circuits, according to the present invention, are selectively addressed by enable signals which are generated from delay memory 34 under control of controller 30. These delay signals are delayed in time with respect to the energization signals being applied to those LEDs which are already in proper registration. The delay time of the signals applied to the misregistered pixels is determined in a way best described with reference to FIGS. 2-4 as follows.
It is assumed that print bar 10 comprises approximately 2550 LEDs (pixels) aligned in a single row to provide a line exposure of 8.5 inches. It is further assumed that the pixels are registered in the linear direction but one or more pixels are out of alignment (misregistered) in the sagital or slow scan direction. FIG. 2 represents a portion of bar 10, showing pixel groups 10A, 10B, 10C, 10D, 10N, some of which are misregistered in the sagital dimension about a given center line. Each group comprises a plurality of LEDs 12, each LED being in registration with other LEDs in that grouping but not necessarily registered with LEDs in the other groups. LED group 10B, for purposes of illustration, is shown out of registration with the other groups 10A, 10C, 10D. It is assumed these latter 3 groups are in the proper registration. The mis-registration is shown in more detail in FIG. 3. There it is seen that group 10B is out of alignment with the pixel groups 10A, 10C, 10D by a distance D d . This distance is hereafter referred to as a delay distance defined as the distance from the leading edge of the group 10B (the misregistered group) to the leading edge of the other 3 groups (the properly registered groups). Assuming the photoreceptor web 14 moves at a constant velocity V pr , the time it takes for a point on the web to move from the leading (right) edge of pixel group 10B to the leading edge of pixel groups 10A, 10C, 10D is a delay time T d which varies in accordance with the expression
T.sub.d =D.sub.d /V.sub.pr (1)
In order to correct for the misregistration condition shown in FIG. 2, the signals from drive circuit 46 which energizes that specific pixel group must be delayed for the time period, T d . The timing delay required can best be understood with reference to FIGS. 4 and 5. FIG. 4 is a timing chart for operating on a 16 pixel LED print bar. The actual duty cycle of the print bar is the ratio of the LED ON time to the total line time T l . When transferred to physical space, the line time (T l ) is generally set to equal the time required for the photoreceptor 16 (at V pr ) to move the slow scan resolution distance of the system. For a 300×300 spi system operating at a V pr of 10 inches per second, the line time (T l ) would equal 333.3 microseconds. Since at least 16 clocks counts would have to occur to clock in all the data through one serial data input line, a minimum clock frequency of 48 kilohertz would be required for this simple imaginary system. If the pixel placement of the first four pixels represented in group 10B of FIG. 3 and a timing sequence such as shown in FIG. 4 was used, pixel group 10B would be misplaced on the photoreceptor by the delay distance D d . To correct for this, the Enable signal for pixel group 10B is delayed by a value determined by the expression given in (Eq 1). A timing sequence incorporating this concept is shown in FIG. 5. From extrapolation, each pixel or pixel group in print bar 10 can be individually addressed so that, if the pixel, or pixel group, is to be energized (turned on) for the partial line scan, and if that pixel, or group, has previously been identified as being misregistered, the energization signal for that group, or plurality of groups, will be delayed with regard to the pixel groups which are in proper registration.
Each print bar would be subject to unique misregistration conditions. Therefore, according to another aspect of the invention, an individual print bar is pre-calibrated so as to identify those LEDs in the print bar which are misregistered and to generate and store appropriate registration correction (enable signals) for those misregistered LEDs. This calibration is accomplished according to the following procedure. A fixture 70, FIG. 1 incorporating CCD camera arrays is mounted to a precision linear scan mechanism located parallel to the LED bar at the image plane. The fixture is scanned under the LED bar and the location of each pixel in the slow scan direction is measured and saved in controller 32 memory. Subsequent post-processing of the position data is entered into the correction logic of ESS controller 30. This information is transferred by computer diskette, E-Prom or direct data transfer. An alternate method is to create a bar code of the measured position information and fix it directly to the LED Bar from which it was measured. Position correction data could then be scanned into the ESS at the time of LED bar installation.
While the above description addresses the specific problem of correcting for pixel to pixel misregistration along a linear print bar, the delayed pixel energization method can be used for other purposes. As one example, consider the hybrid ROS/print bar scan system in FIG. 6. The system is intended to produce color prints from input video data by forming a first latent image on the surface of photoreceptor belt 50 by means of a ROS system, and subsequent latent images in registration with the first ROS latent image, by LED bars 70, 72, the later latent images associated with a specific color to be subsequently developed with the appropriate toner. The system operates as follows: A laser diode 51 serves as the source of high-intensity coherent output beams of light. The laser output is self-modulated and the output beams of light are modulated in conformance with the information contained in a video signal. The modulated beams are expanded and focused by optical elements in a pre-polygon optical subsystem 52, as is known in the art, so that output beams 54A, 54B are formed which are directly incident on a facet 56 of rotating multi-faceted polygon 58. The rotational axis of polygon 58 is orthogonal, or nearly orthogonal, to the plane in which light beams 54A, 54B travels. The facets of polygon 20 are mirrored surfaces which reflect the light impinging thereon. With the rotation of polygon 20 in the direction shown by the arrow, the light beams are reflected from illuminated facet 56 and translated into a scan angle for flying spot scanning. The beam portion 60 reflected from facet 56 passes through an fΘ lens 62 which is designed to focus the beam along the linear focal plane to eliminate the circular arc which is imparted to the beam as it is reflected along the facet surface. The beams are then projected through cylindrical lens 64 which has power only in the sagital direction (orthogonal to the direction of scan).
The focused beam 60 is swept across the surface of belt 50 as a scan line 66 in the direction of arrow 34. Belt 50 is rotated in the process direction shown. Also forming latent images at the surface of belt 50 are print bar 70, 72 which are energized by video data signals applied in the same manner described above in conjunction with the FIG. 1 circuitry. The initial latent image formed by the ROS scanner comprised a plurality of modulated scan lines 66. Each line is conventionally linearized by an fΘ lens to reduce the bow in the scanned line associated with spot reflections from the facet surface of the rotating polygon. However, for some systems, this linearization may yet leave some residual irregularities in the scanned line. This irregular line can be characterized and plotted and the subsequent print bars can be calibrated to print a line which is in registration with the irregular ROS scan line.
For example, as shown in FIG. 7, ROS scan line 66 is shown as comprising two segments, the pixels associated with segment A being in linear registration while the pixels associated with segment B lie along part of an arc or bow. Print bars 70, 72 would first be calibrated, using one of the previously described calibration procedures, to determine the shape of their distinctive scan line. These characterized lines are then conformed to the line 66 in FIG. 7 to determine the appropriate enabling delay signal which must be applied to each group of pixels.
While the invention has been described with reference to the structures disclosed, it is not confined to the details set forth but is intended to cover such modifications or changes as they come within the scope of the following claims.
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An image bar recording system, which, in a preferred embodiment, utilizes an LED image bar, with associated circuitry for recognizing which of individual LEDs comprising the print bar are out of registration in the slow scan, process direction of a moving photoreceptor upon which the image is to be recorded. Modification of the drive circuits to the individual LEDs results in energization signals being delayed to the identified, misregistered LEDs resulting in an exposure line which is in correct slow scan registration.
According to another aspect of the invention, the delayed signals are selectively applied to intentionally cause a misregistered exposure line when using the image bar in conjunction with a raster output scan system.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a continuation of U.S. patent application Ser. No. 12/402,278 filed on Mar. 11, 2009, now U.S. Pat. No. 8,403,856, which is hereby incorporated by reference in its entirety.
BACKGROUND
Intravascular Ultrasound (IVUS) has become an important interventional diagnostic procedure for imaging atherosclerosis and other vessel diseases and defects. In the procedure, an IVUS catheter is threaded over a guidewire into a blood vessel of interest, and images are acquired of the atherosclerotic plaque and surrounding area using ultrasonic echoes. This information is much more descriptive than the traditional standard of angiography, which shows only a two-dimensional shadow of the vessel lumen. Some of the key applications of IVUS include: determining a correct diameter and length of a stent to choose for dilating an arterial stenosis, verifying that a post-stenting diameter and luminal cross-section area are adequate, verifying that a stent is well apposed against a vessel wall to minimize thrombosis and optimize drug delivery (in the case of a drug eluting stent) and identifying an exact location of side-branch vessels. In addition, new techniques such as virtual histology (RF signal-based tissue characterization) show promise of aiding identification of vulnerable plaque (i.e., plaque which is prone to rupture and lead to onset of a heart attack).
There are two types of IVUS catheters commonly in use: mechanical/rotational IVUS catheters and solid state catheters. In a rotational IVUS catheter, a single transducer consisting of a piezoelectric crystal is rotated at approximately 1800 revolutions per minute while the element is intermittently excited with an electrical pulse. This excitation causes the element to vibrate at a frequency dependent upon the particulars of the transducer design. Depending on the dimensions and characteristics of the transducer, this operating frequency is typically in the range of 8 to 50 MHz. In general terms, a higher frequency of operation provides better resolution and a smaller catheter, but at the expense of reduced depth of penetration and increased echoes from the blood (making the image more difficult to interpret). A lower frequency of operation is more suitable for IVUS imaging in larger vessels or within the chambers of the heart.
The rotational IVUS catheter has a drive shaft disposed within the catheter body. The transducer is attached to the distal end of the drive shaft. The typical single element piezoelectric transducer requires only two electrical leads, with this pair of leads serving two separate purposes: (1) delivering the intermittent electrical transmit pulses to the transducer, and (2) delivering the received electrical echo signals from the transducer to the receiver amplifier (during the intervals between transmit pulses). The IVUS catheter is removably coupled to an interface module, which controls the rotation of the drive shaft within the catheter body and contains the transmitter and receiver circuitry for the transducer. Because the transducer is on a rotating drive shaft and the transmitter and receiver circuitry is stationary, a device must be utilized to carry the transmit pulse and received echo across a rotating interface. This can be accomplished via a rotary transformer, which comprises two halves, separated by a narrow air gap that permits electrical coupling between the primary and secondary windings of the transformer while allowing relative motion (rotation) between the two halves. The spinning element (transducer, electrical leads, and driveshaft) is attached to the spinning portion of the rotary transformer, while the stationary transmitter and receiver circuitry contained in the interface module are attached to the stationary portion of the rotary transformer.
The other type of IVUS catheter is a solid state (or phased array) catheter. This catheter has no rotating parts, but instead includes an array of transducer elements (for example 64 elements), arrayed in a cylinder around the circumference of the catheter body. The individual elements are fired in a specific sequence under the control of several small integrated circuits mounted in the tip of the catheter, adjacent to the transducer array. The sequence of transmit pulses interspersed with receipt of the echo signals provides the ultrasound data required to reconstruct a complete cross-sectional image of the vessel, similar in nature to that provided by a rotational IVUS device.
Currently, most IVUS systems rely on conventional piezoelectric transducers, built from piezoelectric ceramic (commonly referred to as the crystal) and covered by one or more matching layers (typically thin layers of epoxy composites or polymers). Two advanced transducer technologies that have shown promise for replacing conventional piezoelectric devices are the PMUT (Piezoelectric Micromachined Ultrasonic Transducer) and CMUT (Capacitive Micromachined Ultrasonic Transducer). PMUT and CMUT transducers may provide improved image quality over that provided by the conventional piezoelectric transducer, but these technologies have not been adopted for rotational IVUS applications due to the larger number of electrical leads they require, among other factors.
There are many potential advantages of these advanced transducer technologies, some of which are enumerated here. Both PMUT and CMUT technologies promise reduced manufacturing costs by virtue of the fact that these transducers are built using wafer fabrication techniques to mass produce thousands of devices on a single silicon wafer. This is an important factor for a disposable medical device such as an IVUS catheter. These advanced transducer technologies provide broad bandwidth (>100%) in many cases compared to the 30-50% bandwidth available from the typical piezoelectric transducer. This broader bandwidth translates into improved depth resolution in the IVUS image, and it may also facilitate multi-frequency operation or harmonic imaging, either of which can help to improve image quality and/or enable improved algorithms for tissue characterization, blood speckle reduction, and border detection. Advanced transducer technologies also offer the potential for improved beam characteristics, either by providing a focused transducer aperture (instead of the planar, unfocused aperture commonly used), or by implementing dynamically variable focus with an array of transducer elements (in place of the traditional single transducer element).
BRIEF SUMMARY
The present invention provides the enabling technology allowing advanced transducer technology to be introduced into a rotational IVUS catheter. This in turn will provide improved image quality and support advanced signal processing to facilitate more accurate diagnosis of the medical condition within the vessel. All of this can be achieved in a cost-effective way, possibly at a lower cost than the conventional technology.
Embodiments of an intravascular ultrasound probe are disclosed herein. The probe has features for utilizing an advanced transducer technology on a rotating transducer shaft. In particular, the probe accommodates the transmission of the multitude of signals across the boundary between the rotary and stationary components of the probe required to support an advanced transducer technology. These advanced transducer technologies offer the potential for increased bandwidth, improved beam profiles, better signal to noise ratio, reduced manufacturing costs, advanced tissue characterization algorithms, and other desirable features. Furthermore, the inclusion of electronic components on the spinning side of the probe can be highly advantageous in terms of preserving maximum signal to noise ratio and signal fidelity, along with other performance benefits.
In a disclosed embodiment, a rotational intravascular ultrasound probe for insertion into a vasculature is described. The rotational intravascular ultrasound probe can comprise an elongate catheter, an elongate transducer shaft, a spinning element, and a motor. The elongate catheter can have a flexible body. The elongate transducer shaft can be disposed within the flexible body and can have a drive cable and a transducer coupled to the drive cable. The spinning element can be coupled to the transducer shaft and can have an electronic component coupled thereto that is in electrical contact with the transducer. A motor may be coupled to the spinning element for rotating the spinning element and the transducer shaft.
In another disclosed embodiment, an interface module for a rotational intravascular ultrasound probe for insertion into a vasculature is described. The interface module can comprise a connector, a spinning element, and a motor. The connector can be used for attachment to a catheter having a transducer shaft with a transducer. The spinning element can be coupled to the connector and can have an electronic component coupled thereto that is in electrical contact with the connector. A motor may be coupled to the spinning element for rotating the spinning element.
In yet another disclosed embodiment, an interface module for a rotational intravascular ultrasound probe for insertion into a vasculature is described. The interface module can comprise a printed circuit board, a connector, a spinning element, and a motor. The connector can be used for attachment to a catheter having a transducer shaft with a transducer. The spinning element can be coupled to the connector. The spinning element has more than two signal pathways electrically connecting the spinning element to the connector. A motor may be coupled to the spinning element for rotating the spinning element.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified fragmentary diagrammatic view of a rotational IVUS probe;
FIG. 2 is a simplified fragmentary diagrammatic view of an interface module and catheter for the rotational IVUS probe of FIG. 1 incorporating basic ultrasound transducer technology;
FIG. 3 is a simplified fragmentary diagrammatic view of an embodiment of an interface module and catheter for the rotational IVUS probe of FIG. 1 incorporating an advanced ultrasound transducer technology;
FIG. 4 is a simplified fragmentary diagrammatic view of another embodiment of an interface module and catheter for the rotational IVUS probe of FIG. 1 incorporating an advanced ultrasound transducer technology;
FIG. 5 is a simplified fragmentary diagrammatic view of another embodiment of an interface module and catheter for the rotational IVUS probe of FIG. 1 incorporating an advanced ultrasound transducer technology; and
FIG. 6 is a simplified fragmentary diagrammatic view of another embodiment of an interface module and catheter for the rotational IVUS probe of FIG. 1 incorporating an advanced ultrasound transducer technology.
DETAILED DESCRIPTION
Turning to the figures, representative illustrations of rotational intravascular ultrasound (IVUS) probes, some of which include active spinning elements, are shown therein. An active spinning element can increase the number of signal paths available for the operation of the transducer so that advanced transducer technologies, such as PMUT (Piezoelectric Micromachined Ultrasonic Transducer) and CMUT (Capacitive Micromachined Ultrasonic Transducer), can be utilized with a rotational IVUS probe. In addition, an active spinning element can include active electronics on the rotary side of the probe.
Referring specifically to FIG. 1 , a rotational intravascular ultrasound probe 100 for insertion into a patient for diagnostic imaging is shown. The probe 100 comprises a catheter 101 having a catheter body 102 and a transducer shaft 104 . The catheter body 102 is flexible and has both a proximal end portion 106 and a distal end portion 108 . The catheter body 102 is a sheath surrounding the transducer shaft 104 . For explanatory purposes, the catheter body 102 in FIG. 1 is illustrated as visually transparent such that the transducer shaft 104 disposed therein can be seen, although it will be appreciated that the catheter body 102 may or may not be visually transparent. The transducer shaft 104 is flushed with a sterile fluid, such as saline, within the catheter body 102 . The fluid serves to eliminate the presence of air pockets around the transducer shaft 104 that adversely affect image quality. The fluid can also act as a lubricant. The transducer shaft 104 has a proximal end portion 110 disposed within the proximal end portion 106 of the catheter body 102 and a distal end portion 112 disposed within the distal end portion 108 of the catheter body 102 .
The distal end portion 108 of the catheter body 102 and the distal end portion 112 of the transducer shaft 104 are inserted into a patient during the operation of the probe 100 . The usable length of the probe 100 (the portion that can be inserted into a patient) can be any suitable length and can be varied depending upon the application. The distal end portion 112 of the transducer shaft 104 includes a transducer subassembly 118 .
The proximal end portion 106 of the catheter body 102 and the proximal end portion 110 of the transducer shaft 104 are connected to an interface module 114 (sometimes referred to as a patient interface module or PIM). The proximal end portions 106 , 110 are fitted with a catheter hub 116 that is removably connected to the interface module 114 .
The rotation of the transducer shaft 104 within the catheter body 102 is controlled by the interface module 114 , which provides a plurality of user interface controls that can be manipulated by a user. The interface module 114 also communicates with the transducer subassembly 118 by sending and receiving electrical signals to and from the transducer subassembly 118 via wires within the transducer shaft 104 . The interface module 114 can receive, analyze, and/or display information received through the transducer shaft 104 . It will be appreciated that any suitable functionality, controls, information processing and analysis, and display can be incorporated into the interface module 114 .
The transducer shaft 104 includes a transducer subassembly 118 , a transducer housing 120 , and a drive cable 122 . The transducer subassembly 118 is coupled to the transducer housing 120 . The transducer housing 120 is attached to the drive cable 122 at the distal end portion 112 of the transducer shaft 104 . The drive cable 122 is rotated within the catheter body 102 via the interface module 114 to rotate the transducer housing 120 and the transducer subassembly 118 . The transducer subassembly 118 can be of any suitable type, including but not limited to one or more advanced transducer technologies such as PMUT or CMUT. The transducer subassembly 118 can include either a single transducer or an array.
FIG. 2 shows a rotational IVUS probe 200 utilizing a common spinning element 232 . The probe 200 has a catheter 201 with a catheter body 202 and a transducer shaft 204 . As shown, the catheter hub 216 is near the proximal end portion 206 of the catheter body 202 and the proximal end portion 210 of the transducer shaft 204 . The catheter hub 216 includes a stationary hub housing 224 , a dog 226 , a connector 228 , and bearings 230 . The dog 226 mates with a spinning element 232 for alignment of the hub 216 with the interface module 214 and torque transmission to the transducer shaft 204 . The dog 226 rotates within the hub housing 224 utilizing the bearings 230 . The connector 228 in this figure is coaxial. The connector 228 rotates with the spinning element 232 , described further herein.
As shown, the interior of the interface module 214 includes a motor 236 , a motor shaft 238 , a printed circuit board (PCB) 240 , the spinning element 232 , and any other suitable components for the operation of the IVUS probe 200 . The motor 236 is connected to the motor shaft 238 to rotate the spinning element 232 . The printed circuit board 240 can have any suitable number and type of electronic components 242 , including but not limited to the transmitter and the receiver for the transducer.
The spinning element 232 has a complimentary connector 244 for mating with the connector 228 on the catheter hub 216 . As shown, the spinning element 232 is coupled to a rotary portion 248 of a rotary transformer 246 . The rotary portion 248 of the transformer 246 passes the signals to and from a stationary portion 250 of the transformer 246 . The stationary portion 250 of the transformer 246 is wired to the transmitter and receiver circuitry on the printed circuit board 240 .
The transformer includes an insulating wire that is layered into an annular groove to form a two- or three-turn winding. Each of the rotary portion 250 and the stationary portion 248 has a set of windings, such as 251 and 252 respectively. Transformer performance can be improved through both minimizing the gap between the stationary portion 250 and the rotary portion 248 of the transformer 246 and also by placing the windings 251 , 252 as close as possible to each other.
Advanced transducer technologies can require more than the two conductive signal lines that a single piezoelectric transducer utilizes on a conventional rotational IVUS probe. For example, in addition to signal pathways for ultrasound information communicated with the transducer, certain advanced transducer technologies also require a power supply in order to operate. In order to pass the necessary multiple of signals between the advanced transducer technology and the interface module, a suitable structure may be needed to transmit ultrasound signals, power, and any other suitable signals across the boundary between the rotating and stationary mechanical components. Particularly for ultrasound signals, the mode of transmission must also maintain reliable signal quality, without excess noise, sufficient for the interface module to form a reliable image of the target tissue from the sensitive ultrasound signals. It will be appreciated that any suitable signals can be communicated across the boundary between the rotating and stationary mechanical components including, but not limited to, A-scan RF data, power transmit pulses, low amplitude receive signals, DC power and/or bias, AC power, and/or various control signals. The signal transfer across the boundary between the rotating and stationary mechanical components can have high frequency capability and broadband response.
Multiple signal transfer pathways are presented herein for communicating signals across the boundary of the rotating and stationary parts. Each of these pathways are explained in further detail herein, and for purposes of discussion and explanation, certain pathways may be shown in combination with one another. It will be appreciated, however, that any of these pathways may be utilized in any suitable combination with one another to permit any suitable number of total signal pathways. Furthermore, as will be explained in further detail below, certain signal transfer pathways can be more conducive to transmitting either power or other signals, such as ultrasound signals.
Referring to FIG. 3 , an embodiment of a rotational IVUS probe 300 having an interface module 314 and catheter 301 suitable for use with an advanced transducer technology is represented. As shown, the probe 300 has a catheter body 302 , a transducer shaft 304 , and a catheter hub 316 . The catheter body 302 has a proximal end 306 and the transducer shaft 304 has a proximal end 310 . The catheter hub 316 includes a stationary exterior housing 324 , a dog 326 , and a connector 328 . The connector 328 is represented with six conductive lines 354 shown in this embodiment. It will be appreciated, however, that any suitable number of conductive lines can be utilized.
As shown, the interior of the interface module 314 can include a motor 336 , a motor shaft 338 , a main printed circuit board (PCB) 340 , a spinning element 332 , and any other suitable components for the operation of the IVUS probe 300 . The motor 336 is connected to the motor shaft 338 to rotate the spinning element 332 . The printed circuit board 340 can have any suitable number and type of electronic components 342 .
The spinning element 332 has a complimentary connector 344 for mating with the connector 328 on the catheter hub 316 . The connector 344 can have conductive lines, such as 355 , that contact the conductive lines, such as 354 , on the connector 328 . As shown, the spinning element 332 is coupled to a rotary portion 348 of a rotary transformer 346 . The rotary portion 348 of the transformer 346 passes the signals to and from a stationary portion 350 of the transformer 346 . The stationary portion 350 of the transformer 346 is electrically connected to the printed circuit board 340 .
In this embodiment, the transformer 346 has multiple sets of windings for transmitting multiple signals across the transformer 346 . Specifically, as shown, the rotary portion 348 and the stationary portion 350 of the transformer 346 each have two sets of windings, such as windings 352 , 353 on the stationary portion 350 and windings 351 , 357 on the rotary portion 348 , to transmit two signals across the transformer 346 . In this way, more signal pathways are available for a probe 300 utilizing an advanced transducer technology. It will be appreciated that any suitable number of windings may be used to transmit any suitable number of signals across the transformer 346 . In alternative embodiments, planar flex circuits can be used in place of the windings in the transformer. The planar flex circuits can be placed very close to one another to enhance signal quality.
Another consideration for advanced transducer technologies is that the probe 300 can benefit from the utilization of certain active electronic components and circuitry in order to facilitate and/or complement the operation of the transducer. Through active electronic components and circuitry on the spinning element 332 , more complex electrical communication can take place between the interface module 314 and the transducer. Furthermore, by handling certain signal processing functions on the spinning element 332 , the number of signals that need to pass across the spinning element 332 can, in some embodiments, be reduced.
As shown, a printed circuit board 356 can be coupled to the spinning element 332 . The printed circuit board 356 can have any suitable number of electronic components 358 coupled thereto. Any suitable number of printed circuit boards 356 having any suitable number and type of electronic components 358 can be utilized on the spinning element 332 . The electronic components on the spinning element 332 allow for signal processing to take place on the spinning side of the probe 300 before the signal is communicated across the rotary/stationary boundary.
Typically, advanced transducer technologies require a DC power source. To provide DC power to the transducer, the spinning element 332 can be fitted with contacts, such as slip ring contacts 360 , 361 , which are respectively engaged by stationary brushes 362 , 363 within the interface module 314 . Each of the slip rings 360 , 361 is coupled to a respective conductive line, such as 355 , in the connector 344 .
In other embodiments, the transducer can be powered by an AC power source. For example, instead of using brushes and contacts, AC power can be transmitted through a set of windings in the transformer 346 . Once the power has passed across from the stationary portion 350 of the transformer 346 to the rotary portion 348 of the transformer 346 , it can be passed to a power supply circuit, such as a diode rectifier, on the spinning element 332 that rectifies the AC power into DC power. The rectifier can be coupled to the printed circuit board 356 on the spinning element 332 as one of the electronic components 358 . After the AC power is converted to DC power, the DC power can be used to power the transducer, as well as the other electronic components 358 included on printed circuit board 356 .
Turning to FIG. 4 , an embodiment of a rotational IVUS probe 400 having an interface module 414 and catheter 401 suitable for use with an advanced transducer technology is represented. As shown, the probe 400 has a catheter body 402 , a transducer shaft 404 , and a catheter hub 416 . The catheter body 402 has a proximal end portion 406 , and the transducer shaft 404 has a proximal end portion 410 . The catheter hub 416 includes a stationary exterior housing 424 , a dog 426 , and a connector 428 . The connector 428 is represented with four conductive lines 454 shown in this embodiment. It will be appreciated, however, that any suitable number of conductive lines can be utilized.
As shown, the interior of the interface module 414 can include a motor 436 , a motor shaft 438 , a main printed circuit board (PCB) 440 , a spinning element 432 , and any other suitable components for the operation of the IVUS probe 400 . The motor 436 is connected to the motor shaft 438 to rotate the spinning element 432 . The printed circuit board 440 can have any suitable number and type of electronic components 442 .
The spinning element 432 has a complimentary connector 444 for mating with the connector 428 on the catheter hub 416 . The connector 444 can have conductive lines, such as 455 , that contact the conductive lines, such as 454 , on the connector 428 . As shown, the spinning element 432 is coupled to a rotary portion 448 of a rotary transformer 446 . The rotary portion 448 of the transformer 446 passes the signals to and from a stationary portion 450 of the transformer. The stationary portion 450 of the transformer 446 is electrically connected to the printed circuit board 440 .
As shown, the rotary portion 448 and the stationary portion 450 of the transformer 446 each have a set of windings 451 , 452 to transmit a signal across the transformer 446 . It will be appreciated that any suitable number of windings may be used to transmit any suitable number of signals across the transformer 446 . In this embodiment, the transformer 446 can be used to transfer the ultrasound signal. It will also be appreciated that a planar flex circuit may be used in place of one or more of the sets of windings as previously described.
The probe 400 can benefit from the utilization of certain electronic components and circuitry in order to facilitate and/or complement the operation of the transducer. As shown, one or more printed circuit boards 456 , 457 can be coupled to the spinning element 432 . The printed circuit boards 456 , 457 can have any suitable number of electronic components, such as 458 and 459 , coupled thereto. It will be appreciated that any suitable number of printed circuit boards 456 , 457 having any suitable number and type of electronic components 458 , 459 can be utilized on the spinning element 432 . Electronic components on the spinning element 432 allow for signal processing to take place on the spinning side of the probe 400 before the signal is communicated across the rotary/stationary boundary.
In this embodiment, power is provided to the transducer using a generator mechanism 464 to generate power locally. As illustrated in the figure, the generator mechanism 464 includes a generator coil 466 and a plurality of stator magnets 468 , 469 . The generator coil 466 can be attached to the spinning element 432 to rotate with the spinning element 432 and generate power. The power generated is AC power, so a power supply circuit, such as a diode rectifier, can be used to convert the AC power into DC power. The rectifier can be coupled to the printed circuit boards 456 , 457 on the spinning element 432 . After rectification, the DC power can be used to power the transducer as well as the other electronic components 458 , 459 included on the printed circuit boards 456 , 457 . It will be appreciated that any suitable generator can be utilized to provide power to the transducer.
Another embodiment of a rotational IVUS probe 500 having an interface module 514 and catheter 501 suitable for use with an advanced transducer technology is represented in FIG. 5 . As shown, the probe has a catheter body 502 , a transducer shaft 504 , and a catheter hub 516 . The catheter body 502 has a proximal end portion 506 , and the transducer shaft 504 has a proximal end portion 510 . The catheter hub 516 includes a stationary exterior housing 524 , a dog 526 , and a connector 528 . The connector 528 is represented with four conductive lines 554 shown in this embodiment. It will be appreciated, however, that any suitable number of conductive lines can be utilized.
As shown, the interior of the interface module 514 can include a motor 536 , a motor shaft 538 , a main printed circuit board (PCB) 540 , a spinning element 532 , and any other suitable components for the operation of the IVUS probe 500 . The motor 536 is connected to the motor shaft 538 to rotate the spinning element 532 . The printed circuit board 540 can have any suitable number and type of electronic components 542 .
The spinning element 532 has a complimentary connector 544 for mating with the connector on the catheter hub 516 . The connector 544 can have conductive lines, such as 555 , that contact the conductive lines, such as 554 , on the connector 528 . As shown, the spinning element 532 is coupled to a rotary portion 548 of a rotary transformer 546 . The rotary portion 548 of the transformer 546 passes the signals to and from the stationary portion 550 of the transformer 546 . The stationary portion 550 of the transformer 546 is electrically connected to the printed circuit board 540 .
As shown, the rotary portion 548 and the stationary portion 550 of the transformer 546 each have one set of windings 551 , 552 to transmit a signal across the transformer 546 . It will be appreciated that any suitable number of windings 551 , 552 may be used to transmit any suitable number of signals across the transformer 546 . In this embodiment, the transformer 546 is used to transfer AC power. Once the power has passed across from the stationary portion 550 of the transformer 546 to the rotary portion 548 of the transformer 546 , it can be passed to a power supply circuit, such as a diode rectifier, on the spinning element 532 that rectifies the AC power into DC power. The rectifier can be coupled to the printed circuit boards 556 , 557 on the spinning element 532 . After the AC power is converted to DC power, the DC power can be used to power the transducer as well as the other electronic components 558 , 559 included on the printed circuit boards 556 , 557 . It will also be appreciated that a planar flex circuit may be used in place of one or more of the sets of windings as previously described.
As previously mentioned, the probe 500 can benefit from the utilization of certain electronic components and circuitry in order to facilitate and/or complement the operation of the transducer. As shown, one or more printed circuit boards 556 , 557 can be coupled to the spinning element 532 . The printed circuit boards 556 , 557 can have any suitable number of electronic components, such as 558 and 559 , coupled thereto. It will be appreciated that any suitable number of printed circuit boards 556 , 557 having any suitable number and type of electronic components 558 , 559 can be utilized on the spinning element 532 . Electronic components 558 , 559 on the spinning element 532 allow for signal processing to take place on the spinning side of the probe 500 before the signal is communicated across the rotary/stationary boundary.
In this embodiment, an optical coupler 570 is used to transmit the ultrasound signal. It will be appreciated that any suitable optical coupler may be used. The optical coupler can have a first end 572 and a second end 574 . The first end 572 can be stationary and receive optical signals from the second end 574 , which can be coupled directly or indirectly to the spinning element 532 . The ultrasound signal can be transmitted to circuitry on the printed circuit board 540 or can be carried external to the interface module 514 .
One illustrative example of how the ultrasound signal could be communicated over this optical path is that the printed circuit boards 556 , 557 could include a high speed analog to digital converter (ADC) among electronic components 558 , 559 . This ADC would be used to digitize the ultrasound echo signal and convert the resultant digital data into a serial bit stream. This serial data would then be provided to an optical transmitter, such as a laser diode circuit, also included on printed circuit boards 558 , 559 to transmit the high-speed serial bit stream over the rotating optical coupler 570 to an optical receiver circuit included on printed circuit board 540 or located remotely from the interface module 514 .
As shown, a structure may be provided that can provide feedback as to the angular position of the transducer. For example, an optical device 576 may be provided that includes a stationary encoder wheel 578 and an optical detector 580 . The optical detector 580 can be attached to a printed circuit board 557 on the spinning element 532 .
Another embodiment of a rotational IVUS probe 600 having an interface module 614 and catheter 601 suitable for use with an advanced transducer technology is represented in FIG. 6 . As shown, the probe 600 has a catheter body 602 , a transducer shaft 604 , and a catheter hub 616 . The catheter body 602 has a proximal end portion 606 , and the transducer shaft 604 has a proximal end portion 610 . The catheter hub 616 includes a stationary exterior housing 624 , a dog 626 , and a connector 628 . The connector is represented with four conductive lines, such as 654 , shown in this embodiment. It will be appreciated, however, that any suitable number of conductive lines 654 can be utilized.
As shown, the interior of the interface module 614 can include a motor 636 , a motor shaft 638 , a main printed circuit board (PCB) 640 , a spinning element 632 , and any other suitable components for the operation of the IVUS probe 600 . The motor 636 is connected to the motor shaft 638 to rotate the spinning element 632 . The main printed circuit board 640 can have any suitable number and type of electronic components 642 including but not limited to the transmitter and the receiver for the transducer.
The spinning element 632 has a complimentary connector 644 for mating with the connector 628 on the catheter hub 616 . The connector 644 can have conductive lines, such as 655 , that contact the conductive lines, such as 654 , on the connector 628 . As shown, the spinning element 632 is coupled to a rotary portion 648 of a rotary transformer 646 . The rotary portion 648 of the transformer 646 passes the signals to and from the stationary portion 650 of the transformer 646 . The stationary portion 650 of the transformer 646 is electrically connected to the printed circuit board 640 .
As shown, the rotary portion 648 and the stationary portion 650 of the transformer 646 each have a set of windings 651 , 652 to transmit a signal across the transformer 646 . It will be appreciated that any suitable number of windings may be used to transmit any suitable number of signals across the transformer 646 . In this embodiment, the transformer 646 is used to transfer AC power. Once the power has passed across from the stationary portion 650 of the transformer 646 to the rotary portion 648 of the transformer 646 , it can be passed to a power supply circuit, such as a diode rectifier, on the spinning element 632 that rectifies the AC power into DC power. The rectifier can be coupled to printed circuit boards 656 , 657 on the spinning element 632 . After the AC power is converted to DC power, the DC power can be used to power the transducer as well as the other electronic components 658 , 659 included on the printed circuit boards 656 , 657 . It will also be appreciated that a planar flex circuit may be used in place of one or more of the sets of windings as previously described.
As previously mentioned, the probe can benefit from the utilization of certain electronic components and circuitry in order to facilitate and/or complement the operation of the transducer. As shown, one or more printed circuit boards 656 , 657 can be coupled to the spinning element 632 . The printed circuit boards 656 , 657 can have any suitable number of electronic components, such as 658 and 659 , coupled thereto. It will be appreciated that any suitable number of printed circuit boards 656 , 657 having any suitable number and type of electronic components 658 , 659 can be utilized on the spinning element 632 . Electronic components 658 , 659 on the spinning element 632 allow for signal processing to take place on the spinning side of the probe 600 before the signal is communicated across the rotary/stationary boundary.
In this embodiment, a wireless communication mechanism is used to transmit the ultrasound signal. Any suitable wireless communication mechanism may be used including, but not limited to, wireless mechanisms utilizing radio frequency or infrared. As shown, the wireless communication mechanism includes transmitter and/or receiver components 682 and 684 . The transmitter and/or receiver component 682 can be attached to any suitable location such as the printed circuit board 657 on the spinning element 632 . The transmitter and/or receiver component 684 can likewise be placed in any suitable location including the main printed circuit board 640 in the interface module 614 .
Therefore, it will be appreciated that signals can be carried across the rotating and stationary mechanical components via any suitable mechanism including, but not limited to, a transformer, an optical coupler, a wireless communication mechanism, a generator, and/or brushes/contacts. In certain embodiments, a transformer, an optical coupler, and/or a wireless communication mechanism can be utilized to carry signals such as an ultrasound signal. In certain embodiments, a transformer, a power generator, and/or brushes/contacts can be utilized to convey power to the transducer.
Furthermore, the spinning element can have one or more printed circuit boards with a suitable number and type of active electronic components and circuitry, thus making the spinning element an active spinning element. Examples of electronic components that can be utilized with the active spinning element include, but are not limited to, power supply circuits (such as a generator, rectifier, regulator, high voltage step-up converter, etc.), transmitters (including tripolar transmitters), time-gain-control (TGC) amplifiers, amplitude and/or phase detectors, ADC converters, optical transceivers, encoder circuits, wireless communication components, microcontrollers, and any other suitable components. In addition, the spinning element can include encoder and timing logic such that it can internally generate the transmit triggers, and thus, eliminate the need to communicate a timing signal across the spinning element. Through the embodiments described herein, excellent image quality is possible including wide bandwidth, frequency-agility, low ringdown, focused beam (including dynamically focused beam), and harmonic capability.
As mentioned, any suitable advanced transducer technology may be used, including but not limited to PMUT and CMUT transducers, either as single transducers or arrays. As an example, a PMUT transducer can be formed by depositing a piezoelectric polymer (such as polyvinylidene fluoride—PVDF) onto a micromachined silicon substrate. The silicon substrate can include an amplifier and protection circuit to buffer the signal from the PVDF transducer. It can be important to include the amplifier immediately adjacent to the PVDF element because the capacitance of the electrical cables can dampen the signal from the high impedance PVDF transducer. The amplifier typically requires DC power, transmit input(s), and amplifier output connections. The PVDF transducer can be a focused transducer to provide excellent resolution.
As mentioned above, having an active spinning element, such as is described herein, permits the utilization of an advanced transducer technology on a rotational IVUS probe. In addition, having an active spinning element can facilitate certain advanced operations of the probe. The enhanced bandwidth of the probe utilizing the active spinner permits the probe to obtain information at a plurality of different frequencies. By way of example and not limitation, the probe can be utilized to obtain ultrasound information taken at two diverse frequencies, such as 20 MHz and 40 MHz. It will be appreciated that any suitable frequency and any suitable quantity of frequencies may be used.
Generally, lower frequency information facilitates a tissue versus blood classification scheme due to the strong frequency dependence of the backscatter coefficient of the blood. Higher frequency information generally provides better resolution at the expense of poor differentiation between blood speckle and tissue, which can make it difficult to identify the lumen border. Thus, if information is obtained at a lower frequency and a higher frequency, then an algorithm can be utilized to interleave and display the two data sets to obtain frequency-diverse information that is closely aligned in time and space. In result, a high resolution ultrasound image can be produced with clear differentiation between blood and tissue and accurate delineation of vessel borders.
The typical 512 A-lines that compose a single frame of an image can be interspersed into alternating high and low frequency A-lines. As an example, a 20 MHz image can show the blood as black and the tissue as gray, while the 40 MHz image can show the blood and tissue as gray and barely, if at all, distinguishable from one another. It can be recognized through a provided algorithm that black in 20 MHz and gray at 40 MHz is blood, gray at both frequencies is tissue, and black at both frequencies is clear fluid. The broadband capability of advanced transducer technologies, such as PMUT, facilitated by the active spinning element, can allow for closely interleaved A-lines of two or more different center frequencies, possibly including pulse-inversion A-line pairs to generate harmonic as well as fundamental information, which is then combined to provide a robust classification scheme for tissue versus blood.
The dual frequency blood classification scheme can be further enhanced by other blood speckle reduction algorithms such as motion algorithms (such as ChromaFlo, Q-Flow, etc.), temporal algorithms, harmonic signal processing, etc. It will be appreciated that any suitable algorithm can be used.
Besides intravascular ultrasound, other types of ultrasound catheters can be made using the teachings provided herein. By way of example and not limitation, other suitable types of catheters include non-intravascular intraluminal ultrasound catheters, intracardiac echo catheters, laparoscopic, and interstitial catheters. In addition, the probe may be used in any suitable anatomy, including, but not limited to, coronary, carotid, neuro, peripheral, or venous.
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.
It will be appreciated that like reference numbers and/or like shown features in the figures can represent like features. It will be appreciated that discussions of like reference numbers and/or like shown features in any embodiment may be applicable to any other embodiment.
Any references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein (including any references contained therein).
Illustrative embodiments of a rotational IVUS probe incorporating an advanced ultrasound transducer technology are described herein. Variations of the disclosed embodiments will be apparent to those of ordinary skill in the art in view of the foregoing illustrative examples. Those skilled in the relevant art will employ such variations as appropriate, and such variations, embodied in alternative embodiments, are contemplated within the scope of the disclosed invention. The invention is therefore not intended to be limited to the examples described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.
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An intravascular ultrasound probe is disclosed, incorporating features for utilizing an advanced transducer technology on a rotating transducer shaft. In particular, the probe accommodates the transmission of the multitude of signals across the boundary between the rotary and stationary components of the probe required to support an advanced transducer technology. These advanced transducer technologies offer the potential for increased bandwidth, improved beam profiles, better signal to noise ratio, reduced manufacturing costs, advanced tissue characterization algorithms, and other desirable features. Furthermore, the inclusion of electronic components on the spinning side of the probe can be highly advantageous in terms of preserving maximum signal to noise ratio and signal fidelity, along with other performance benefits.
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RELATED APPLICATION(S)
[0001] This application claims the benefit of U.S. Provisional Application Ser. No. 60/765,528, filed on Feb. 6, 2006, the entire teachings of which are incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] For the most part, Electronic Flight Information Systems (EFIS) have replaced conventional aircraft electromechanical flight instruments for displaying primary flight and navigational data to an aircraft pilot or a member of the aircrew. EFIS systems present all information necessary for a current phase of flight in a compact display. An EFIS system typically includes an engine indication and crew alerting system (EICAS) display, a multi-function display (MFD), and a primary flight display (PFD).
[0003] The EICAS displays information about an aircraft's systems, such as the fuel, electrical systems, and propulsion systems. An EICAS display typically mimics conventional round (circular) gauges while supplying digital readouts of the measured parameters.
[0004] The EICAS improves situational awareness by allowing aircrew members to view complex information in a graphical format. The EICAS also can alert the aircrew members to unusual or hazardous situations. For example, if an engine begins to lose oil pressure, the EICAS can sound an alert (alarm), switch the display to the page with oil system information and outline the low oil pressure data with a red box. Unlike conventional round gauges, a user can set many levels of warnings and alarms.
[0005] The MFD displays navigational and weather information received from multiple systems. Typically, an MFD is “chart-centric”, where aircrew members can overlay different information over a map or chart. For example, MFD overlay information can include an aircraft's current route plan, weather information, restricted airspace information, and aircraft traffic information. The MFD can also view non-overlay types of data (e.g., current route plan) and calculated overlay types of data (e.g., the glide radius of the aircraft, given current location over terrain, winds, and aircraft speed and altitude).
[0006] As with the EICAS, the MFD can display information about aircraft systems, such as fuel and electrical systems. The MFD can improve a pilot's situational awareness by changing the color or shape of the data to alert aircrew members to hazardous situations (e.g., low airspeed, high rate of decent, terrain warnings).
[0007] The PFD displays all information critical to a flight, including airspeed, altitude, heading, attitude, vertical speed and yaw. The PFD improves a pilot's situational awareness by integrating this information into a single display instead of six different analog (conventional) instruments, thereby reducing the amount of time necessary to monitor the instruments.
[0008] As with the MFD, the PFD increases situational awareness by alerting aircrew members to unusual or potentially hazardous conditions by changing the color or shape of the display and/or by providing audio alerts.
SUMMARY OF THE INVENTION
[0009] Although these systems provide increased situational awareness, a need exists to combine weather information and terrain warnings onto a Navigation Display (ND), (e.g. a PFD) to provide the pilot with a navigational aide for avoiding these conditions.
[0010] The present invention provides a method and system for displaying critical navigational data on a primary flight display to a pilot of an aircraft. The method includes providing an image representative of weather information on a primary fight display and superimposing an image representative of a terrain warning indicator over at least part of the image representative of weather information.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The foregoing and other objects, features and advantages of the invention will be apparent from the following more particular description of preferred embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention.
[0012] FIG. 1A is an illustration of a Primary Flight Display (PFD) showing the flight status of an aircraft on the top half and a navigation status on the bottom half, the navigation status including weather information.
[0013] FIG. 1B is an illustration of a PFD showing the flight status of an aircraft on the top half and a navigation status on the bottom half, the navigation status including terrain caution information overlaid with weather information.
[0014] FIG. 1C is an illustration of a PFD showing the flight status of an aircraft on the top half and a navigation status on the bottom half, the navigation status including terrain warning information overlaid with weather information.
[0015] FIG. 2A is an illustration of a Multi-Function Display (MFD) showing the position of an aircraft and terrain information proximate to the flight path of the aircraft.
[0016] FIG. 2B is an illustration of a MFD showing the position of an aircraft and terrain information and warnings proximate to the flight path of the aircraft.
[0017] FIG. 3A is an illustration of a MFD showing the position of an aircraft, and terrain information and weather information proximate to the flight path of the aircraft.
[0018] FIG. 3B is an illustration of a MFD showing the position of an aircraft, and terrain information and warnings and weather information proximate to the flight path of the aircraft.
DETAILED DESCRIPTION OF THE INVENTION
[0019] FIG. 1A illustrates a primary flight display (PFD) 100 utilizing the concepts of the present invention. The PFD 100 includes multiple windows for displaying mission critical information. For example, the HDG BUG 102 is a heading indicator that shows an overhead illustration of the heading of the aircraft 104 with relation to the ground. The HDG BUG 102 can include an indication of a flight path 110 of the aircraft and image 120 representative of the weather conditions/information. The flight path 110 includes flight legs 112 a , 1122 b . . . 112 n bounded by waypoints 114 a , 114 b . . . 114 n . It should be understood that the inventive concepts can be used on any flight display.
[0020] The image 120 representative of weather conditions/information provides the pilot with increased situational awareness and reduces the possibility of accidents associated with flying into severe weather conditions. Weather data/information is received from ground, satellite, weather datalink, radar and other known in-flight weather systems. The intensity of the weather is shown ranging from green to red, wherein green 122 is the lowest intensity (e.g., light rain), yellow 124 is moderate intensity (e.g. light to heavy rain), and red 126 is severe intensity (e.g., heavy rain, thunderstorms). Although the present invention uses green, yellow, and red colors as warning indicators it should be known to one skilled in the art that any colors, patterns, or symbols known in the industry can be used.
[0021] As shown in FIGS. 1B-1C , a Terrain Awareness System is used to provide the pilot with increased situational awareness and reduce the possibility of accidents associated with Controlled Flight Into Terrain (CFIT). Thus, while the aircraft is in flight, calculations are being made as to the height of the terrain in the aircraft's flight path 110 . The calculation is generated from a database of terrain heights and the aircraft's position, as determined by a GPS receiver connected to the EFIS. The calculation may also be generated by ground mapping radar or terrain sensors. If it is determined the aircraft is in danger of CFIT, a terrain warning indication 130 is superimposed over the image 120 representative of weather conditions.
[0022] The terrain warning indication 130 provides a caution indicator 132 a ( FIG. 1B ) if the aircraft is within one-minute of CFIT and a severe indicator 132 b ( FIG. 1C ) if the aircraft is within thirty seconds of CFIT. The color associated with the caution indicator 132 a is yellow, while the color associated with the severe indicator 132 b is red. The terrain warning indication 130 encompasses the hazardous terrain condition within a set boundary while allowing the pilot to view the image 120 representative of weather conditions. This provides the pilot with optimal situational awareness since the pilot can make a decision based on both hazardous conditions simultaneously.
[0023] The terrain warning indication 130 is shown as a waffle-type like pattern. The waffle-type like pattern includes opaque blocks representative of terrain mapping information and translucent rows and columns for allowing the pilot to view through the terrain warning indication 130 . The opaque blocks can be any shape known for displaying terrain mapping information.
[0024] Although extreme weather conditions and CFIT can be hazardous to an aircraft, there is a greater probability of flying through an extreme weather condition than there is hitting an object. Thus, the image 120 representative of weather conditions is dimmed an amount in relation to the terrain warning indication 130 depending upon the proximity of the aircraft to the hazard. The image 120 representative of weather conditions, for example, can be dimmed by twenty-five percent while the aircraft is one-minute of CFIT. The image 120 representative of weather conditions, for example, can be dimmed by fifty percent while the aircraft is thirty seconds of CFIT. The image 120 representative of weather conditions is not completely turned off because it allows the pilot to make an informed decision based on both hazardous conditions simultaneously. It should be understood that variations to the time and dimming intensity can vary.
[0025] FIG. 2A illustrates a multifunction flight display (MFD) 200 utilizing the concepts as described with reference to FIGS. 1A-1C . In one embodiment, an image 210 representative of terrain conditions within the aircraft's flight path is displayed on the MFD 200 . The height of the terrain is shown ranging from green to red, wherein green 212 a is no danger (e.g., low terrain), yellow 212 b is moderate danger (e.g. terrain close to height of aircraft), and red 212 c is severe danger (e.g., terrain at or above height of aircraft). This embodiment allows the pilot to view actual terrain heights, thereby allowing the pilot to make an informed decision based on the height of the terrain. As shown in FIG. 2B , the terrain warning indication 130 is displayed if the aircraft is in danger of CFIT.
[0026] FIG. 3A illustrates a multifunction flight display (MFD) 200 utilizing the concepts as described with reference to FIGS. 1A-2B . In another embodiment, an image 120 representative of weather conditions and an image 210 representative of terrain conditions within the aircraft's flight path are displayed on the MFD 200 . This embodiment allows the pilot to view actual terrain heights along with weather conditions, thereby allowing the pilot to make an informed decision on both hazardous conditions simultaneously. As shown in FIG. 3B , the terrain warning indication 130 is displayed if the aircraft is in danger of CFIT.
[0027] While this invention has been particularly shown and described with references to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention encompassed by the appended claims.
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The present invention provides a method and system for displaying critical navigational data on a primary flight display to a pilot of an aircraft. The method includes providing an image representative of weather information on a primary fight display and superimposing an image representative of a terrain warning indicator over at least part of the image representative of weather information.
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BACKGROUND OF THE INVENTION
Ethylenimine (EI) is an active three-membered cyclic amine and is a very useful compound since it can introduce an amino group by an addition reaction, substitution reaction, ring opening reaction and the like. Ethylenimine is especially important as an aminoethylation agent of compounds containing an active hydrogen. It is also useful as a monomer for polyamine-type polymers in homo and co-polymerizations. In addition to all of these uses, it is also possible to prepare derivatives which retain the ring opening reactivity of ethylenimine through an addition reaction of the amino group. All of these features make ethylenimine an important substance both chemically and industrially.
Ethylenimine can be synthesized by one of several methods. One is the Gabriel method in which a beta-halo-ethylamine undergoes a ring closure through a treatment with a concentrated base or silver oxide. Another involves the reaction of ethylene chloride (1,2-dichloroethane) with anhydrous ammonia in the presence of a base. This reaction and equivalent reactants for form EI and substituted EI's are disclosed in U.S. Pat. No. 3,336,294. Yet another preparation of EI involves a decomposition (ring closure) of monoethanolamine sulfuric acid ester by hot concentrated base. Each of the above methods present certain disadvantages. For example, it is necessary to control the reaction conditions strictly to synthesize both beta-haloethyl amine and monomethanolamine sulfuric acid ester. The syntheses tend to be accompanied by side reaction and side products. All of these problems make these starting materials very expensive. At the same time, the halogen and sulfuric acid ester group which are introduced in the syntheses are removed in the subsequent process making these syntheses wasteful from the stand point of the functional group utilization. Furthermore, both processes use a base for the ring closure reaction. The bases most often used are sodium hydroxide and potassium hydroxide and these bases are used as concentrated solutions in large quantities. Thus the base requirement per ethylenimine unit is very high and uneconomical. The by-products, NaCl, Na 2 SO 4 or the potassium equivalents, are a further expense since they have little value and must be disposed of. The lost chlorine values in the method using 1,2 dichloroethane makes this process an expensive one. None of the art processes are readily made continuous so as to be more attractive commercially.
A more recent process involving the vapor phase dehydration of monoethanolamine is disclosed in Japanese Patent Publication No. 50-10593/1975. A catalyst of tungsten oxide alone or preferable with another metal oxide as an assistant is employed. The metal oxide assistant includes lithium, magnesium, tin, bismuth, molybdenum, nickel and aluminum oxides.
Such assistants or promoters may be added to the catalyst in known manner by depositing a promoter metal or oxide on the catalyst support either prior to, coincidentally with or after the deposition of the catalytic material. The reaction is conducted at a temperature of 350° C. to 450° C. preferably using an inert diluent gas such as ammonia or nitrogen. Conversions of up to 45% and selectivities of as high as 66% are reported.
It has now been discovered that a coating of silica over a tungsten oxide catalyst improves its life and maintains the selectivity and conversion close to the 50% level. Without the silica addition both selectivity and conversion fall off rapidly.
SUMMARY OF THE INVENTION
An inert support, e.g. silicon carbide, is coated with tungsten oxide by soaking the support in a solution containing a soluble salt of tungsten, e.g. ammonium metatungstate, after which it is dried and calcined. Thereafter it is soaked in a colloidal solution of SiO 2 dried and calcined to provide a coating of silica on the surface of the catalyst.
Tungsten catalysts prepared according to the art have the tendency to diminish in activity and selectivity over a relatively short period of time. The present invention is the discovery that a coating of silica on the surface of such a catalyst effectively prevents the diminution of activity.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is an improved catalyst which is useful for the dehydration of alkanolamine to make alkylenimines. The catalyst is prepared by a known method, i.e. soaking a support in an aqueous solution of the soluble metal salt of tungsten. After removing excess solution and drying the tungsten oxide is formed by calcining the impregnated support in air at a temperature in the range of 500° to 900° C. for a period of time of from 1 to 4 hours. In like manner the tungsten oxide catalyst which has been soaked in the silica solution is again calcined in air for 1-3 hours at 350°-500° C.
The catalyst supports suitable for the present invention are inert low surface area materials such as silicon carbide, spinel, alumina, and magnesium-alumina silicate. The surface area of such supports should be from about 0.02 to about 1 m 2 /g.
The amount of tungsten oxide deposited on the support should be in the range of from 5 to 50% and preferably from about 27 to 43% based on the support and catalyst. The promoter, i.e. silicon dioxide, is preferably applied at a concentration of from 1 to about 10% based on total weight of catalyst.
In the process of dehydration, the molar ratios of the feed components may vary from 12.6 to 33.1 ammonia and 7.4 to 32.8 nitrogen per mole of alkanolamine.
The following examples show the preparation and use of the catalysts of the art and of the present invention.
EXAMPLE 1
(Comparative)
A tungsten catalyst was prepared in the manner of the prior art in the following manner: Ammonium metatungstate (137.9 gms) was dissolved in 250 mls of deionized water. This solution was then added to 280 gms of low surface area 3/16 inch spherical silicon carbide support. The excess water was removed on a steam bath and the supported catalyst oven dried at 150° C. for one hour. The catalyst was then air-calcined in a furnace for four hours at 710° C. using an air flow of 15 SCF/hr. Loading of tungsten oxide on the support was 29.8 wt. %.
EXAMPLE 2
About 75 ml of this catalyst was loaded into a 3/4 inch I.D. stainless steel single tube reactor and run under the following conditions: reactor temperature--400° C.; ammonia--3626 mls/min.; nitrogen--300 mls/min.; liquid monoethanolamine--0.35 mls/min.; liquid water--0.8 mls/min.
With a 31.4% MEA conversion, the selectivity to EI dropped from 41% to 14% over a two-hour period. After regeneration with air and steam at 400° C. for 11/2 hours, MEA conversion was 23% with EI selectivity at a high of 12.2% down to 4% after 2 hours.
EXAMPLE 3
(Comparative)
To prepare the catalyst of the present invention 124.1 gms of ammonium metatungstate was dissolved in 250 mls of deionized water. This solution was then added to 230 gms of low surface area 3/16 inch spherical silicon carbide support. The excess water was removed on a steam bath and the supported catalyst oven dried at 150° C. for one hour. The catalyst was then calcined in an air furnace for four hours at 715° C. and 15 SCF hr air. Loading of tungsten oxide on the support was 33.2 wt. %. Surface area of support (finished catalyst) was 0.13 m 2 /gm.
EXAMPLE 4
(Invention)
Half of the above catalyst (Example 3) was soaked in a 10% solution of colloidal silicon dioxide for a few minutes. The excess was drained off and the catalyst oven dried at 150° C. for one hour and calcined in an air furnace as described above. A 2.68 wt. % loading of silicon dioxide was burdened on the catalyst. Surface area was 2.47 m 2 /gm.
Into a 3/4 inch I.D. stainless steel single tube reactor 75 mls of each of the catalysts was loaded and run under the conditions shown in the Table below.
__________________________________________________________________________Catalyst Temp. Feed Composition (ml/min)Example% WO.sub.3 % SiO.sub.2 (°C.) NH.sub.3 N.sub.2 MEA* Water* Conv. % Sel. %__________________________________________________________________________3 (Comp)33.2 -- 410 3625 350 0.4 0.8 24.2 13.04** 33.2 2.68 410 3625 350 0.4 0.8 17.9 41.55 11.3 3.64 410 909 2980 0.4 0.8 35.6 56.06 30.7 1.94 410 909 2980 0.4 0.8 25.0 50.97 22.8 2.87 400 909 2980 0.4 0.8 63.7 58.98 30.7 1.17 410 3625 350 0.4 0.8 28.5 53.3__________________________________________________________________________ *MEA, water amounts are expressed as liquid rather than vapor as with NH.sub.3 and N.sub.2. **Catalyst of Example 3 ran all day without a die off, but was then subjected to a regeneration treatment as in Example 2 with air and steam for one hour at 410° C. and run the next day at 17.8% MEA conversion. The EI selectivity increased to 52.2%. Catalyst was run for five days with selectivity increasing with each regeneration.
The regeneration can be conducted at 300° to 500° C. for 1 to 3 hours.
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A dehydration catalyst containing tungsten oxide on a low surface area support and having a silica coating thereon. The catalyst has increased life and is useful for the dehydration of alkanolamines in making alkylenimines, e.g. ethanolamine is dehydrated to ethylenimine.
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BACKGROUND OF THE INVENTION
The U.S.A. Pat. No. 3,405,795 of the same applicant relates to an apparatus for stowing and conveying articles, particularly for use in parking motor vehicles, comprising at least one plurality of supporting and conveying units mutually interconnected at predetermined intervals, movable in a continuously horizontal position on an endless runway formed by fixed tracks for guiding the supporting members of said units. The most important characteristics of this apparatus, ad claimed by said patent, are as follows:
CONTINUITY OF SUPPORT BY SAID TRACKS AND BY AUXILIARY FIXED MEANS ASSOCIATED THEREWITH IS PROVIDED FOR THE SUPPORTING AND CONVEYING UNITS THROUGH THE WHOLE RUNWAY, THE MEANS FOR INTERCONNECTING THE UNITS ALSO SERVING TO PRODUCE THE CONTROL MOVEMENTS;
SAID SUPPORTING UNITS ARE CONSTITUTED BY CARRIAGES PROVIDED WITH WHEELS FOR THEIR SUPPORT ON SAID TRACKS, SAID TRACKS COMPRISING ON EACH SIDE OF THE CARRIAGES A PAIR OF PARALLEL HORIZONTAL LENGTHS, COMMON TO THE TWO WHEELS ON THE SAID SIDE, AND FOUR PAIRS OF INCLINED PARALLEL LENGTHS, WHICH DIVERGE OUTWARDLY SUBSTANTIALLY AT THE ENDS OF THE SAID HORIZONTAL LENGTHS WITH EQUAL AND OPPOSITE INCLINATIONS, ONE FOR EACH WHEEL ON THE SAME SIDE;
SAID FIXED MEANS ASSOCIATED WITH THE TRACKS ARE CONSTITUTED BY PAIRS OF WHEELS, MOUNTED IDLE IN THE CONNECTION REGION OF THE UPPER HORIZONTAL TRACK LENGTH WITH THE TWO INCLINED LENGTHS, AND APT TO SUPPORT THAT CARRIAGE END WHICH HAS LEFT THE TRACK IN THE GAP THEREIN;
THE MEANS FOR INTERCONNECTING AND MOVING THE CARRIAGES ARE CONSTITUTED BY ROTATING CHAINS, MOUNTED OFFSET ON THE TRACKS ON ONE SIDE AND THE OTHER OF THE CARRIAGES, AND EACH BEING CONNECTED TO ONE OF THE TWO CARRIAGE AXLES;
The individual loads are transferred from the carriages to the loading and unloading level and viceversa by elevators situated within the endless runway of the supporting unit, said elevators being capable of vertically moving the supporting floors of the carriages with their load and, in the event that the apparatus should comprise various pluralities of concentric supporting units, of passing through the carriages without said floor provided in each plurality.
The apparatus described in U.S.A. Pat. No. 3,405,795 is essentially an apparatus contained in a reinforced concrete or metal cage, arranged below ground level, although the said patent specification explicitly provides also for its surface installation.
The practical construction of this apparatus and the increasing requirements of mechanisation and speed of operation in the field of goods storage and vehicle stowing , have led to further study and improve the apparatus itself.
In the course of these studies, substantial improvements have been obtained, which have enabled the apparatus for stowing and conveying articles, as heretofore defined, to be improved structurally and operationally, and to make its field of possible application much wider.
SUMMARY OF THE INVENTION
These improvements constitute the object of the present invention, which therefore relates to an apparatus for stowing and conveying articles of the type heretofore defined, comprising several pluralities of supporting units, in side-by-side horizontal arrangement and in overlying vertical arrangement, the transfer of the individual loads, from the supporting units of each plurality to the loading and unloading level and viceversa, being effected at the horizontal ends of the endless runway of the supporting units by transelevators, the transfer platform of which is apt to move both ways, in the direction in which said pluralities of supporting units are arranged side-by-side and in the vertical direction.
In an apparatus of this type, each transelevator comprises a tower structure, movable in the direction in which the pluralities of supporting units are arranged side-by-side, and a transfer platform, movable vertically in said tower, said transfer platform being in the form of a floor translating towards the pluralities of supporting units and in the opposite direction.
Alternatively, the transelevators may move relative to the pluralities of supporting units in other suitably chosen directions.
The present invention provides the specific application of the said apparatus, not only to the stowing and conveying of vehicles, particularly motor vehicles, but also to the stowing and handling of loads and goods of any kind, and in particular to the stowing and storing of containers, either on the ground, on boats or on the mooring docks for such boats.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is illustrated hereinafter in greater detail, by way of example, with reference to the accompanying drawings, in which:
FIG. 1a is a side elevational section of one embodiment of the apparatus according to the invention;
FIG. 1b is a plan sectional view of FIG. 1a;
FIG. 1c is an end elevational view of FIG. 1a;
FIG. 2a is a side elevational section of one embodiment of the invention utilized at dockside;
FIG. 2b is a perspective view of FIG. 2a;
FIG. 3a is a side elevational section of a ship utilizing one embodiment of the present invention;
FIG. 3b is an end elevation of the ship of FIG. 3a;
FIG. 3c is a plan view of the ship of FIG. 3a;
FIG. 4a is a side elevational section of the embodiment of the invention utilized in the storage and movement of goods;
FIG. 4b is a plan sectional view of FIG. 4a;
FIG. 4c is an end elevational section of FIG. 4a;
FIG. 5a is a side elevational section illustrating the invention when utilized for storing and moving automobiles;
FIG. 5b is an end sectional view of FIG. 5a;
FIG. 6a is a side elevational section illustrating the invention when utilized for storing and moving goods;
FIG. 6b is an end sectional view of FIG. 6a;
FIG. 7a is a side elevational view of the invention illustrating automobiles in the transverse position to their movement;
FIG. 7b is a side elevational view of the invention illustrating the possible simultaneous loading or unloading of a plurality of automobiles;
FIG. 8 is a perspective view of another embodiment of the invention as applied to loading for storage and unloading from storage automobiles;
FIG. 9 is a perspective view of an embodiment of the invention as applied to loading and unloading goods;
FIG. 10 is a side elevational view of an embodiment of the invention permitting the loading and unloading of automobiles outside of the storage area;
FIG. 11 is an end elevational view of FIG. 10;
FIG. 12a is a perspective view of the transfer platform of the invention to the right of the tower uprights;
FIG. 12b is a perspective view of the transfer plaform of the invention to the left of the tower uprights;
FIG. 13 is a plan view of the platform of FIG. 12b; and
FIG. 14 is a detailed end elevational section of a portion of the tower and platform of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to the drawings, FIG. 1 shows an apparatus according to the invention used as an underground garage for a large building F. The apparatus comprises four side-by-side assemblies 1 for stowing and conveying motor vehicles, in accordance with U.S.A. Pat. No. 3,405,795, each of these assemblies being formed by three concentric pluralities 2 of supporting units 3 mobile in an endless loop and continuously supported in a horizontal position. Each assembly 1 comprises an elevator 4, arranged at the centre of the most inner of the pluralities 2, for the odd assemblies of support units, and displaced towards one end or the other, for the even assemblies. In this manner, it is possible to stow a considerable number of motor vechicles underground, over the area of a building and, by playing upon the distribution of the entrances I to the building (the ground floor of which coincides with the loading and unloading level for the automobiles), a rapid and confortable access to the apparatus may also be obtained during rush hours.
FIG. 2 of the drawings relates to the stowing and conveying of goods held in containers on a port dock B. The apparatus according to the invention, which rises from the dock floor, is formed in this case by a multiplicity of assemblies 11 of pluralities 12 of supporting units 13, which are mobile along a closed circuit and are supported continuously in a horizontal position, each assembly 11 comprising two concentric pluralities 12 served by two end elevators 14. Special container cranes 15 and 16, adapted to serve cargo boats N and trucks A, for conveying the handled containers 17 by sea and land, cooperate with these elevators.
The boats N may themselves house an apparatus according to the invention, as shown in FIG. 3, with obvious advantage for the loading and unloading of the goods.
FIG. 3 shows a diagrammatic representation of a boat N comprising internally an apparatus formed by seven assemblies 21, each with two concentric pluralities 22 of supporting units 23 for containers 24, a central elevator 25 being provided for each assembly 21.
The improved apparatus of FIG. 4 is also provided for storing goods, in this case in the form of ordinary packing cases 31. The apparatus is housed in a basement S of a building F, the loading and unloading dock of the apparatus, situated under the projecting roof T of the building, coinciding with street level P. The apparatus according to the invention in this case comprises four assemblies 32 of two concentric pluralities 33 of supporting units 34, mobile along a closed circuit and continuously supported in a horizontal position. Each assembly is served by an elevator 35. The apparatus also comprises two loading and unloading docks 36 alternative to the dock P. These docks, which are connected to the interior of the building F, for example by goods elevators, are served by lift trucks 37. This application is particularly suitable for a department store or supermarket, as the goods may be stowed directly outside the halls of the department store. Thus, reception or withdrawal of the goods can be carried out by a single control, and the goods undergo no other handling. Moreover, the goods may remain on their own support in the apparatus, independently of the manoeuvres of the other supports.
As stated, FIGS. 5, 6 and 7 illustrate three garages of limited size, which may be constructed with the apparatus according to the invention in an extremely simple and economical manner.
In FIG. 5, a single plurality 41 of supporting units 42 is used, its upper track 43 being at the level of the loading and unloading dock 44, to allow direct access by the driver without requiring other means for transferring the motor vehicles 45. The apparatus may be partially below ground level or it may take advantage of slight variations of level in the ground surrounding a building, as shown in FIG. 5, in which the cage 46 containing the apparatus is of tubular structure.
While in FIG. 5 the apparatus has only one loading and unloading dock, the apparatus shown in FIG. 6--which is identical to the previous apparatus, except for the parallelepiped form of the containing cage 49--comprises one loading and unloading dock at each end (48 and 49 respectively). It is mounted outside and requires a difference in level between said docks 48 and 49.
FIG. 7 shows a garage, which can be easily constructed by using prefabricated elements, and which is characterised by the possiblity of simultaneously delivering a large number of automobiles. A single plurality 51 of supporting units 52 is used and one of their tracks 53 is arranged at street level, onto which opens a very wide access bay 54. A large number of automobiles 55 may simultaneously travel to or from their supporting units by moving transversely to the main extension of the apparatus, instead of parallel to it, as in the example shown in FIGS. 5 and 6.
FIGS. 8 to 14 relate to a particularly complete and sophisticated embodiment of the apparatus according to the invention, designed to take account of the most modern requirements.
At the present time, the stowing, loading and unloading of motor vehicles, goods and materials, frequently have to take place in very different positions, according to service and handling requirements, and dependent on the volume, weight and position of their arrival at the stowing point and their destination for use, these different positions being dictated by reasons of speed and economy and to avoid increased use of personnel or auxiliary means for their transfer.
To this end, the most up-to-date technique uses increasingly automated mechanisation of movement, which also comprises complex electronically controlled systems. The apparatus according to the present invention, shown in FIGS. 8 to 14, utilises such a technique and satisfies all existing requirements very simply and economically. By its means, it is possible to send to its destination or receive an automobile or any other material or goods to be stowed, without the load ever being moved on to other tracks or ancillary means. The article to be stowed always travels on its own single track, independently of level differences and of the areas requested by service requirements, this being very important for operational speed and installation economy. The apparatus also comprises various entrance and exit systems of independent and simultaneous operation, leading to faster and more rational working, with smaller times and greater economy.
The extrance and exit systems may be provided vertically and horizontally. Entry may take place on one side and exit on the other side, or in another part, or even at different levels, without the use of further means. The entrances and exits may be provided below ground, at street level or in elevation. Finally, the tracks may be of any line or shape, and may be vertical, horizontal, elliptical, circular, stepped or of other more suitable forms, providing they produce a single closed circuit.
On this basis, consideration will first be given to FIGS. 8 and 9. These relate to the same type of apparatus, but designed for two different purposes, namely, the stowing of atuomobiles 61 in FIG. 8 and the stowing of containers 62 (or packing cases of other types of goods of any kind) in FIG. 9. Both apparatuses comprise pluralities 63 of supporting units 64 in side-by-side and overlying relationship, which are mobile in a closed circuit and continuously supported in a horizontal position. The arrangement so obtained is in the form of rows and columns. This arrangement is served by various transelevators 65 (FIGS. 8 and 9 show four of these) which may be arranged on the sides of the apparatus facing the horizontal ends of the pluralities 63 of supporting units, as shown in the figures, but which could also be arranged to the side of said pluralities, on the other two sides of the apparatus, or into inner corridors formed in the apparatus parallel to said pluralities. It is also evident that the apparatus could comprise side-by-side blocks, such as those shown in FIGS. 8 and 9, separated by corridors traversed by transelevators.
In FIGS. 8 and 9, the apparatuses according to the invention rise from the loading and unloading dock, placed at ground level. There would obviously be no conceptual difference if they were constructed underground or partly underground.
The illustrated transelevators 65 are transfer devices, comprising a tower 66 apt to translate parallel to the side of the apparatus which it serves, and a transfer platform 67 mobile vertically. They are therefore able, with great operational flexibility, to transfer loads from the loading dock at ground level onto any plurality in the column of the apparatus which they face, or from any plurality of any column to the plurality of another column in the same row, if limited to the elementary movements of the platform 67 or tower 66 respectively. However it is clear that combined movements of the tower and platform enable any desired load transfer in the row and column arrangement of the apparatus, to be made with extreme ease, speed and operational flexbility.
Other types of transelevators may be used with advantage. For example, transelevators with their tower moving along paths other than the path parallel to the side of the apparatus served, and operating partly as a lift truck.
FIGS. 10 to 14 show in detail the characteristics of the transelevators purposely designed for the apparatus of FIG. 8 and similar apparatuses.
These figures show that a transelevator 65 comprises a tower structure 66, formed by two uprights arranged side-by-side and guided lowerly and upperly by rails 68, 69, this latter being a rack rail, and a platform structure 67, mobile vertically along the tower 66. The reference number 70 indicates an electric motor, which imparts the translation movements on the transelevator tower, while the reference numbers 71 and 72 indicate an electric motor and cable, which impart the vertical movement on the platform 67.
FIGS. 10 and 11 are very diagrammatic and show how it is possible to take an automobile 61 at ground level, by means of the platform 67, raise it to the level of the plurality 63 of supporting units 64, as the platform itself moves progressively towards the overlying pluralities in the apparatus, and deposit it on a supporting unit 64 in an end position. As can be seen from these same figures, transfer is effected with the aid of a square or rectangular loading plate 73, provided with four feet 74 at its corners, so that it is possible for the transfer platform 67 to be inserted from all sides under the plate, between said feet, for its movement.
FIGS. 12 to 14 are detailed views, illustrating the transfer platform 67 constituted of a device in the form of a loading floor subject to translational movement. This device comprises: substantially rectangular metal half-box members 75, for load bearing purposes, supported close to the uprights of the tower 66 on which they slide, by metal cables 72 which provide their vertical movement; second rectangular half-box members 76, slidably mounted in the half-box members 75; a pair of rectangular box members 77, slidably mounted in the half-box members 76; and a roller carpet structure 78, the rollers 79 of which are idly mounted on the two box members 77. The roller carpet structure comprises a reinforced region 79 on the carpet, acting as loading floor. The device also comprises a reduction motor 80, with three gearwheels 81, 82, 83 keyed on to its shaft and engaged with the racks 84, 85, 86, provided respectively on the half-box members 76, on the box members 77 and on the edges of the carpet 78. It is apparent that, when the reduction motor 80 rotates, the half-box members 76, the box members 77 and the carpet 78 move at different speeds, to cause the horizontal movement of the entire transfer platform 67 in respect of the uprights of the tower 66. The speeds are adjusted in such a manner that the region 79 of the carpet 78, acting as loading floor for the loading plates 73, moves from one end position to the other while the same occurs for the entire platform, as is clear from FIG. 12 which illustrates these positions. By means of this system, all the elements of the moving floor platform are moved together by a single motor, without the need for gears and/or transmissions between the elements.
The same transelevators may be used for the apparatus of FIG. 9, with the difference that during the loading and unloading at street level, the containers or other cases are placed on the loading plates 73, or withdrawn therefrom, by cranes or lift trucks, while the automobiles to be stowed in the apparatus of FIG. 8, are usually arranged on or taken from said plates directly by the driver.
It is understood that the apparatuses described and illustrated are given by mere way of example, and that many other modifications thereof could be provided without departing from the scope of the invention. Thus, the transelevators associated with the apparatus could be of different form and characteristics from those shown in the accompanying drawings or briefly described. For example, they could be provided with an operating cab for an operator, in the event of having to carry out, for special reasons, all or some of the loading and unloading operations non-automatically. Also the arrangement of the various pluralities of supporting units forming the apparatus, may be different from the very simple type of arrangement illustrated, to enable it to be adapted to the requirements of use, to the site on which the installation is constructed or to the special requirements or intentions of the apparatus. Several assemblies of pluralities of supporting units may be grouped or combined, and some assemblies or some pluralities of supporting units may be different from others, especially with regard to their configuration and extension.
The equipment for stowing and conveying articles according to the present invention provides important advantages, and considerable problems in the field of stowing and handling articles are solved, with particular reference to the case in which these articles are automobiles (and more generally motor vehicles) and containers (or more generally cases of large size). These advantages are mainly:
the provision of apparatuses apt to form simultaneously a conveyor, a mobile store, a garage;
the construction of apparatuses with an access and withdrawal system which may be multiple, with the simultaneous operation of different lines;
access and withdrawal in said system may take place on the same side, or on different sides and at different levels, with the possibility of interchange;
the installation lines arranged side-by-side may alternatively be insulated to obtain controlled temperatures therein;
the apparatuses may operate and have entrances and exits underground, at street level or in elevation. They may also be used on vehicles and especially on boats;
there is always great facility, speed and simplicity of access and withdrawal of the articles, even in the case of stowing very large quantities of articles, providing one chooses the most suitable solution out of the many solutions supplied by the present invention.
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An apparatus for stowing and conveying articles comprises at least one plurality of supporting and conveying units mutually interconnected at predetermined intervals, movable in continuously horizontal positions on an endless runway formed by fixed tracks for guiding the supporting members of said units, continuity of support by said tracks and by auxiliary fixed means associated therewith being provided for the supporting or conveying units through the whole runway, the means for interconnecting the units also serving to produce the control movements. In said apparatus are provided several pluralities of supporting units in side-by-side horizontal arrangement and in overlying vertical arrangement, the transfer of the individual loads from the supporting units of each plurality to the loading and unloading level and vice versa, being effected at the horizontal ends of the endless runway of the supporting units by transelevators, the transfer platform of which is apt to move both ways, in the direction in which said pluralities of supporting units are arranged side-by-side and in the vertical direction.
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BACKGROUND OF THE INVENTION
The present invention relates generally to a circuit for improving the rise time of an electronic signal, and more particularly to an assist circuit for improving the rise time of signals on conductors of an open-drain NMOS data transfer bus in a data processing system.
Data processing systems contain data transferred buses such as, for instance, a data bus between a processor and a memory. Assist circuits are known which, at or near the beginning of the processor to memory cycle, supply current to each conductor in the data bus to quickly set each conductor in the data bus to its inactive state. By use of such assist circuits, the processor does not need to supply all of the current to return the conductors in the data bus to their inactive states, but needs only to change selected conductors in the data bus to their active states which correspond to data to be transferred. In prior known bus assist circuits, the supply of current to the data bus conductors is controlled by a clock circuit which also controls the processor to memory cycle.
SUMMARY OF THE INVENTION
In the present invention, a circuit for improving the rise time of an electronic signal includes a voltage generator for generating a reference voltage, a comparator for comparing the voltage of an electronic signal whose rise time is to be improved with the voltage of the reference voltage generator, and a current pulse generator controlled by the comparator for generating a current pulse of a predetermined duration responsive to the comparison of the comparator. The current pulse is of sufficient magnitude to assist the rise time of the electronic signal.
The circuit of the present invention is particularly useful in a data processing system including the NCR-32 VLSI chip set available from the NCR Microelectonics Division, Colorado Springs, Colo., as explained in the publication NCR/32 General Information, RM-0480.
It is thus an object of the present invention to provide an assist circuit for improving the rise time of an electronic signal, from which a trigger signal is derived.
A further object of the present invention is to provide a bus assist circuit for assisting the rise time of an electronic signal on a data bus of a data processing system.
A further object of the invention is to provide a bus assist circuit for a data bus of a data processing system which does not have to be tuned to operate responsive to clock signals from a clock in the data processing system, but rather is triggered by a condition of an electronic signal on the data processing bus itself.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a simplified data processing system utilizing the bus assist circuit of the present invention;
FIG. 2 is a schematic diagram of the bus assist circuit of FIG. 1; and
FIG. 3 is a diagram showing voltage waveforms of the bus voltage both with and without the bus assist circuits of FIGS. 1 and 2, and voltage waveforms at other nodes in the bus assist circuits of FIGS. 1 and 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a block diagram of a simplified data processing system having a data bus conductor (10) of a data bus extending between VLSI chips 12 and 14. The VLSI chips 12 and 14 may be selected from among the NCR/32 chip sets as described in the aforementioned publication RM-0480. For instance, chip 12 may be a central processor chip, and chip 14 may be an address translation chip. It will be understood that the data bus conductor 10 may extend to other devices in a data processing system such as memory or peripherals, or other known data processing devices. As is known, within the VLSI chips are bus driver circuits represented by the N-Channel enhancement MOS transistor 16 which are turned on and off by the circuitry of the VLSI chip to change the state of the signal on the data conductor 10, from its inactive state to its active state. In the illustrated embodiment, the inactive state of a signal on the data bus is a high, and the active state is a low.
It will be understood that at the end of a data cycle, old data must be removed from the bus conductor 10, and new data must be placed on the bus conductor 10 by the proper data processing element, before a new data cycle can be started. For instance, if the signal on the data bus conductor 10 was low, or active, and the new data requires that the signal on the conductor go to its high or inactive state, then the new data cannot be read from the data bus until the change from the low active state to the high inactive state on that conductor has been accomplished. The bus assist circuit of the present invention does this by monitoring the voltage state on each bus conductor 10 of the data bus. When the voltage on a bus conductor 10 rises by a predetermined amount, a pulse of current is input by the bus assist circuit of the present invention to bus conductor 10. This results in a shortened rise time of the voltage level on that conductor, thus shortening the time needed for the voltage on the bus conductor 10 to recover, thereby shortening the time needed between reading data from the data bus.
A load resistor 18 is provided having one end connected to a voltage source V DD at terminal 20, and its other end connected to the data bus conductor 10. An equivalent capcitance 22 is shown between the bus conductor 10 and ground and is added to the diagram of FIG. 1 for clarity only. The capacitor 22 represents the equivalent capacitance presented by the VLSI chips 12 and 14 connected to the bus conductor 10 plus the distributed capacitance of this conductor. It has been found that this equivalent capacitance represented by capacitor 22 may be as high as 100 picofarads. In order to keep the RC time constant within the desired range, the load resistor 18 of the present embodiment is sized to be equal to or greater than 680 ohms to guarantee acceptable logic low level at the data bus conductor 10.
The bus assist circuit of the present invention is represented by circuit 24 of FIG. 1, and includes a reference voltage generator 26, a voltage level sensor circuit 28 which senses the voltage level on the bus conductor 10 and compares it to the output voltage of the reference voltage generator 26, a one-shot circuit 30 which is triggered by the output of level sensor circuit 28, and an output driver circuit 32 controlled by the one-shot circuit 30 for outputting a current pulse, over output conductor 34, to the data bus conductor 10 in the data bus.
FIG. 3 shows a portion of voltage waveforms on the bus conductor 10, both without the bus assist circuit 24 of FIG. 1, and with the bus assist circuit 24. Waveform 100 is the normal voltage on the bus conductor 10 during the rise time of the voltage as it would appear without the bus assist circuit 24, and waveform 102 is the voltage on the bus conductor 10 with a shortened rise time due to the presence of the bus assist circuit 24. Waveform 104 is the voltage on the drain of a voltage level comparator transistor 38 of the voltage level sensor 28, to be discussed, and waveform 106 is the gate voltage of a driver transistor 54 of the output driver circuit 32, to be discussed.
The reference voltage generator 26 may be any one of the various known reference voltage generator circuits. The output 36 of of the reference voltage generator 26 outputs a constant voltage of about 2.2 volts (see V REF of FIG. 3) which is applied to the gate of an N-channel enhancement MOS transistor 38 whose source is connected by conductor 40 to the output conductor 34 of the bus assist circuit 24. The drain of transistor 38 is connected to the source of an N-channel depletion transistor 42 whose drain is connected to the voltage source V DD at terminal 44, as shown. The transistor 38 acts as a comparator for the level sensor circuit 28. The transistor 38 is turned on when the voltage on data bus conductor 10 is low thereby grounding the current output of transistor 42. It will be understood that when the voltage on the source of transistor 38 rises sufficiently close to the reference voltage on the gate of the transistor 38, that the gate to source voltage will be less than the threshold voltage of transistor 38, and the transistor 38 will turn off. Thus, when the voltage on the data bus conductor 10 rises between 0.63 and 0.76 volts (V 1 and V 2 of FIG. 3, respectively), the transistor 38 turns off, thereby diverting the current output from transistor 42 to the output of the level sensor circuit 28.
The output of the level sensor circuit 28 is connected to the input of the one-shot circuit 30 which includes a NAND gate 46, and a series of three inverters 48, 49 and 50. The series of inverters 48, 49 and 50 act as a timing device predicating a fixed length of time for the input signal to be propagated through the series to the NAND gate 46. It will be understood that the timing of the one-shot device may be lengthened or shortened by adding or removing inverters, but that the number of inverters should be an odd number to accomplish the one-shot operation of the circuit. In the disclosed embodiment, the propagation time of the series of inverters 48, 49 and 50 is a total of about 10 nanoseconds (t 1 of FIG. 3).
As the voltage on the bus conductor 10 goes low, the output of the level sensor circuit 28 will be pulled low, driving its subsequent inverter 48 to output a high, the inverter 49 to output a low and the inverter 50 to output a high. This high will be applied to one input of NAND gate 46, while the other input of NAND gate 46 was already at low, following immediately the output of the level sensor circuit 28. Thus, with one input low and one input high, the output of NAND gate 46 will be high. This high will be outputted by the one-shot circuit 30 to the input of the output driver circuit 32.
The output driver circuit 32 includes a predriver inverter 52, and a driver transistor represented by an N-channel enhancement MOS transistor 54. The source of transistor 54 is connected to the output conductor 34, the gate is connected to the output of pre-driver inverter 52, and the drain is connected to the voltage source V DD at terminal 56. Thus, in the condition previously explained, the high from NAND gate 46 is applied to the input of inverter 52 which is converted to a low on the gate of transistor 54 holding transistor 54 in the off condition.
As the voltage on bus conductor 10 rises to somewhere between 0.63 and 0.76 volts, transistor 38 is turned off as previously explained. The current from transistor 42 is increasingly applied to the input of one-shot circuit 30 causing the voltage thereon to rise to a high (see 104 of FIG. 3). This high is applied to the input of NAND gate 46 which, with the prior high on its other input, changes its output to a low. This low is inverted by pre-driver inverter 52 of the output driver circuit 32 to a high which is applied to the gate of transistor 54, turning on transistor 54 and allowing current to pass from the voltage source terminal 56 to the output conductor 34 onto the data bus conductor 10. It will be understood that the transistor 54 will not turn on until the difference between its gate voltage (waveform 106 of FIG. 3) and the voltage on the bus conductor 10 (waveform 102 of FIG. 3) exceeds the threshold voltage of the transistor 54, in this case about 0.566 volts.
The high on the input of one-shot circuit 30 is also applied to the series of inverters made up of inverters 48, 49 and 50. After the approximately 10 nanosecond propagation time of the series of inverters 48, 49 and 50, (t 1 of FIG. 3), the output of inverter 50 goes low, which with the high on the other input of NAND gate 46 causes the output of the NAND gate 46 to go high. This high is inverted by pre-driver inverter 52 to a low which is applied to the gate of transistor 54, thereby turning off transistor 54 and terminating the current output by the bus assist circuit 24 after the 10 nanosecond period. It will be understood that the transistor 54 turns off at 112 of FIG. 3 when the difference between its gate voltage of waveform 106 and the voltage of waveform 102 on the bus conductor 10 falls below the threshold voltage of the transistor 54.
When the voltage on the bus conductor 10 again drops to its active state by the action of, for instance, a bus driver transistor 16, the voltage on the source of the transistor 38 will drop sufficiently below the output voltage from reference voltage generator 26 on the gate of transistor 38. Transistor 38 will turn on, grounding the current from transistor 42, causing the voltage on one input of NAND gate 46 to be low and the voltage on the other input, from inverter 50, to be low. Thus, the output of NAND gate 46 will stay high, which will be inverted by inverter 52, thereby holding transistor 54 off.
After the propagation time of the inverter series 48, 49 and 50, the output of the inverter 50 will change to high. The output of the NAND gate 46 will still remain high, which is inverted by the predriver circuit 52 to hold transistor 54 off. In this manner, the circuit will be reset to assist the next rise of voltage on the data bus conductor 10 as previously explained.
FIG. 2 is a schematic diagram of the bus assist circuit of FIG. 1, showing the connection of the bus driver transistors of the VLSI chips 12 and 14, the connection of the equivalent parasitic capacitance represented by capacitor 22, and the connection of pull-up resistor 18. The numbers beside the transistors, such as 100/4 next to transistor 38, represents the physical dimensions of the polysilicon gate of the transistors in microns. Thus, for transistor 38, the polysilicon gate is 100 microns wide and 4 microns long. It will be noted that the gate of the bus driver transistors of VLSI chips 12 and 14, such as transistor 16, is 1,400 microns wide and 4 microns long. This represents a large current sink which, when turned on, rapidly discharges the voltage on the data bus conductor 10. Transistors 38, 42 and 54 are the same as the transistors shown in FIG. 1. The reference voltage generator 26 of FIGS. 1 and 2 is also the same. N-channel depletion MOS transistor 62 and enhancement transistor 60 of FIG. 2 form inverter 48 of FIG. 1. Transistors 65 and 64 of FIG. 2 form inverter 49 of FIG. 1, and transistors 67 and 66 of FIG. 2 form inverter 50 of FIG. 1. Transistors 69 and 68 form a superdriver output for the inverter 50 of FIG. 1.
Transistors 70, 71, 72, 73, 74 and 75 of FIG. 2 form the NAND gate 46 and a superdriver output for the NAND gate 46 of FIG. 1. Transistors 76, 77, 78 and 79 of FIG. 2 form the pre-driver inverter 52 of FIG. 1, and its superdriver output. Transistor 80 is used to provide a low impedance path for quickly pulling-up the gate of the output transistor 54 of the output circuit 30 of FIG. 1.
The bus assist circuit shown in FIG. 2 may be built with standard N-channel MOS transistors based on 3 and 4 micron polysilicon gate technology. The enhancement and depletion transistors shown are of the single threshold voltage type. Simulation of the bus assist circuit shown in FIG. 2 indicates that the rise time of an electronic signal on the data bus conductor 10 is shortened by 25% compared to the rise time on a conductor without the use of the bus assist circuit.
Thus, there has been shown and described a bus assist circuit which improves the rise time of an electronic signal on a data bus conductor of a data processing system wherein the voltage condition of the electronic signal is used to trigger the bus assist circuit. The described bus assist circuit, and its components, are exemplary only and may be replaced by equivalents by those skilled in the art, which equivalents are intended to be covered by the attached claims.
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A circuit for improving the rise time of an electronic signal including a voltage generator for generating a reference voltage, a comparator for comparing the voltage of an electronic signal whose rise time is to be improved with the voltage of the reference voltage generator, and a current pulse generator controlled by the comparator for generating a current pulse of a predetermined duration responsive to the comparison of the comparator. The current pulse is of sufficient magnitude to assist the rise time of the electronic signal.
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BACKGROUND OF THE INVENTION
This invention relates to methods and products in the utilization and conversion of ash resulting from the incineration of municipal solid wastes, in the form of aggregates useful in asphaltic and portland cement concrete mixes which meet 1990 Federal drinking water standards as defined by the U.S. Environmental Protection Agency.
Municipal solid waste handling and disposal has received substantial attention by agencies of the United States Government as well as by interested environmental groups. For the purpose of this application, municipal solid waste (MSW) is defined as the gross product which is collected and processed by municipalities and governments.
MSW includes durable and non-durable goods, containers and packaging, food and yard wastes, and miscellaneous inorganic wastes from residential, commercial and industrial sources. Examples include newsprint, appliances, clothing, scrap food, containers and packaging, disposable diapers, plastics of all sort including disposable tableware and foamed packaging materials, rubber and wood products, potting soil, yard trimmings and consumer electronics, as part of an open-ended list of disposable or throw-away products. The broad spectrum of MSW content is described in "Characterization of Municipal Solid Waste in the United States: 1990 Update", United States Environmental Protection Agency (EPA), Publication EPA/530-SW-90-042 dated June 1990.
A substantial portion of the total available MSW is being reduced by fire incineration either by mass burn or through combustion of refuse-derived fuel (RDF). While incineration remains controversial, it continues to find increasing acceptance due to a number of factors which include the greatly decreased amount of residual material which must be landfilled, and to improved operating procedures which emit lower concentrations of pollutants into the atmosphere. The use of incineration is increasing and as of 1990, over 160 incinerators were combusting about 10-15% of the MSW generated in this country.
The by-product of MSW incineration is ash, called "MSW ash". The ash represents about one-fourth of the mass of material prior to incineration. Generally, two types of incinerator systems are in use. The first type is called a mass burn system. These are large facilities, usually having a capacity of over 200 tons per day, which burn the unprocessed mixed MSW in a single combustion chamber, usually under conditions of excess air. A second system is one where the MSW is first processed by mechanical means to produce a more homogeneous fuel, It is known as refuse-derived fuel (RDF), which material is then combusted in a boiler, to form a residue in the form of ash.
Both major systems, as well as secondary or smaller systems known as modular systems, are capable of recovering energy from the burn, usually in the form of steam or electric energy, and produce ash as a solid waste by-product of combustion. The subject matter of this invention resides in the fixation and pelletization of products derived from MSW ash, which products meet 1990 Federal drinking water standards for toxins and hazardous materials, including heavy metals.
The term "ash" as used herein encompasses the gross residue from the incineration of MSW following an initial beneficiation to remove the gross or oversized, non-combustion or non-crushable objects. The gross ash content is classified as either "fly ash" or "bottom ash." Typically, the fly ash fraction amounts to from about 5-15% of the total ash and comprises lighter particles which are carried off the burning grate by the convection or turbulence, and condense or form in the flu gas system. Fly ash is removed by precipitators or collection bags in a baghouse. Fly ash can also include the superheater or economizer ash which collects on internal parts of the boiler system which are blown down or removed from time to time and combined with the fly ash fraction. The fly ash also frequently contains spent lime from an air quality control system (AQCS) in which a lime reagent is sprayed into the flue gases to neutralize sulfur dioxide and hydrochloric and hydrofluoric acids. The hot flue gases evaporate the water portion leaving a dry powder residue which is removed in a baghouse and combined with the fly ash. The AQCS fly ash may be combined with bottom ash, or maintained separately and stored in dry silos, depending on the particular plant operations.
"Bottom ash" is the coarse ash residue which accumulates on the grate. It usually falls directly into a water quench pit or tank from which it is removed to a storage area. When MSW is incinerated, a portion of the original material will be non-combustible and will emerge from the incineration process with the bottom ash. This residue contains such items as bottles, cans, rocks, metal, slag, and certain organic wastes, and for the purpose of this invention it is assumed that such gross material, as previously mentioned, is removed at a first classification, usually at the burn facility, for by-pass disposal, such as in landfill.
A consideration of the toxic and non-toxic residues in the ash requires an appreciation of the care which is taken, at the burn site, to segregate or to refuse delivery of unacceptable waste. For example, at the Hennepin County Waste-to-Energy Facility, Hennepin County, Minn., such items as explosives, pathological and biological wastes, radioactive material, incinerator residue, sewage and cesspool sludge, human and animal wastes, large motor vehicle parts, tires, farm machinery, transformers, trees, liquid wastes and other such wastes are refused entry, and thus do not form part of the MSW or its ash. Nevertheless, a broad spectrum of inorganic and organic compounds are necessarily subjected to incineration, and certain portions of these elements and compounds are found in the incinerator ash. While it may be possible for the ash to contain hazardous organic materials such as dioxins and furans, tests have shown that these are well below the levels considered harmful where the ash is collected from a facility which is properly operated to maintain a desired combustion temperature and combustion retention time.
Major inorganic components include aluminum, calcium, chlorine, iron, silicon, sodium and zinc as major components, along with carbon. The ash may also contain a broad range of trace metals, including the eight RCRA priority metals (As, Ba, Cd, Cr, Hg, PB, Se, Ag), as well s copper, cobalt, nickel and tin. In a typical facility, the major components may be identified in combined ash as shown in Table 1.
TABLE 1______________________________________Silicon Dioxide 40% or greaterAluminum Oxide 10-20%Iron Oxide 10-20%Magnesium Oxide 1-6%Sodium Oxide 1-6%Potassium Oxide 1-6%Sulfate Ion 1-6%Chloride Ion 1-6%Phosphate Ion 1-6%______________________________________
The ranges of the small or trace amounts of inorganic elements are represented by Table 2, in terms of pounds of material per ton of combined ash, representing a typical analysis.
TABLE 2______________________________________CONCENTRATIONS OF INORGANICELEMENTS IN COMBINED ASH FROMMUNICIPAL WASTE INCINERATORSElements Pounds/Ton of Ash______________________________________Arsenic * to 0.10Barium 0.16 to 5.40Cadmium * to 0.20Chromium 0.02 to 3.00Lead 0.06 to 73.20Mercury * to 0.04Selenium * to 0.10Silver * to 0.19Aluminum 10.00 to 120.00Antimony <0.24 to <0.52Beryllium * to *Boron 0.05 to 0.35Calcium 8.2 to 170.00Cobalt * to 0.18Copper 0.08 to 11.8Iron 1.38 to 267.00Lithium 0.01 to 0.074Magnesium 1.40 to 32.00Manganese 0.03 to 6.26Molybdenum * to 0.58Nickel 0.03 to 25.82Phosphorous 0.58 to 10.00Potassium 0.58 to 24.00Silicon 2.76 to 392.14Sodium 2.20 to 66.60Strontium 0.02 to 1.28Tin 0.03 to 0.76Titanium 2.00 to 56.00Vanadium 0.03 to 0.30Yttrium * to 0.02Zinc 0.18 to 92.00______________________________________ (Excluding oxygen, sulfates and chlorine) *Less than 1/100 of a pound
Many of the inorganic constituents, or contaminants, have unlikely sources. Cadmium comes from metal coatings and platings on "white goods" such as home appliances, rechargeable batteries, printing inks and color pigments. Lead may originate in rust-proofing paints, wire and cable insulation, bottle caps, and the contact bases of burned-out light bulbs. Mercury is found in disposable batteries, such as hearing aid batteries, power control switches, certain paints, and fluorescent lights. Plastic materials are also a major source of lead and cadmium. Nickel-cadmium batteries include both nickel and cadmium.
Conventionally, the fly ash is combined with the bottom ash at the burn facility for transport to landfill. Only a small portion of the ash has found acceptance for commercial utilization, and in such instances where the resultant product is exposed to humans, there has been lacking an assurance that the material has been processed to recognized or particular EPA standards.
If the fly ash and spent lime fraction are combined with the bottom ash for treatment or disposal, the combined ashes will have moisture content of about 15-20%. The fly ash plus spent lime fraction is itself dry but is hygroscopic in nature and will absorb a portion of the moisture present in the bottom ash, thus reducing the overall combined ash content, when combined. The bottom ash moisture content is substantially higher, averaging 20-30%, where the fly ash is handled and stored separately, such as in dry bins.
Prior attempts at utilization, which have involved processing or treatment for hazardous materials or components, have generally failed to take advantage of the fact that the ash fractions themselves have differing concentrations of certain metals and other possible contaminants, and since they are formed and collected at physically separated locations, the fly ash fraction and the bottom ash fraction may be treated separately by processes tailored to the particular component or group of components in the fraction to be brought within required specifications.
In particular, the Resource Conservation and Recovery Act (RCRA) and the regulatory agencies operating under the Act (Public Law 94-580 (1976)) as Amended and as defined in Title 40 of the Code of Federal Regulations (40 CPR 142), have established maximum safe limits for solid waste and for drinking water as set out below in milligrams per liter:
TABLE 3______________________________________Federal Drinking Water Limits as Mg/l Solid 1990 Federal Waste Drinking WaterRCRA Metals Limits Standards______________________________________Arsenic 5.0 0.05Barium 100.0 1.00Cadmium 1.0 0.01Chromium 5.0 0.10Lead 5.0 0.05Mercury 0.2 0.002Selenium 1.0 0.01Silver 5.0 0.05______________________________________
The drinking water standards for the eight RCRA priority metals set out above are 1/100th of that of the corresponding solid waste limits. Prior processes and techniques have not produced an economically useful product from MSW ash which meets federal drinking water standards when measured by the Toxicity Characteristic Leaching Procedure (TCLP) and as defined at 51 Fed Register 21648, Jun. 13, 1986 and in EPA Method 1311.
The TCLP leaching test has been found to be more aggressive than the extraction procedure toxicity test (EP-TOX) in the measurement of leaching potential, due to the lower pH (2.88) of the TCLP fluid #2. The repeatability of the results by different laboratories following the TCLP procedure makes it superior to the EP-TOX.
The TCLP procedure has now been adopted by the EPA as a replacement for the EP-TOX (EPA method 1310). The aggressiveness of the TCLP test requires that new approaches and methods for economic utilization of MSW ash be developed.
In order to make an economic use of a substantial part of the municipal solid waste ash produced at any given facility, it is necessary to process and convert the ash into a useable end product. If such product is used to add bulk to asphaltic or portland cement concrete mixes it may do so as an aggregate, but first must be converted to a suitable aggregate form, such as by pelletizing. Therefore, in addition to the fixation or chemical treatment of targeted components or elements, the end product must also meet those physical standards which have been created and promulgated for aggregates. These standards relate not only to sieve analysis and specific gravity, but also relate to other required properties of the product including hardness and durability in relation to resistance to abrasion, soundness and resistance to sulfate, resistance to freezing and thawing, and absorptivity. Thus, even though a synthetic by-product of MSW ash may be rendered inert by processing to the levels of federal drinking water standards, nevertheless such product would have restricted or limited commercial use if it failed to conform to the physical standards for such products.
SUMMARY OF THE INVENTION
This invention is directed to the manufacture of an economically useful product from MSW ash. In the preferred form, the product consists of an aggregate which is composed primarily of processed MSW ash which has been rendered environmentally acceptable, and a suitable cementitious material and pozzolan.
The pelletized aggregate is a cold bonded portland cement product as finished or formed in a pan pelletizer. The rounded pellet is both strong and durable, and meets the physical and chemical requirements for such aggregates so as to be fully acceptable as an aggregate for use in portland cement concrete, and for use in asphaltic concrete. Unpelletized material may be used as a sand substitute, provided that it has undergone chemical fixation.
The method produces an aggregate pellet in which the leachable dioxins and furans are either non-existent or practically unmeasurable, in which the leachable RCRA priority metals are at or below specified federal drinking water standards, and in which the aggregate complies with mechanical and physical specifications. In a preferred procedure, the pellets are coated with one or more materials which provide specific properties useful for the mix intended. Thus, where the pellets are intended to be used in an asphalt mix, relatively low absorption as well as a desirable quick lime interface surface can be achieved by applying a light powder of -200 mesh calcium oxide and hydrating the same to cause it to swell and harden on the surface and in the microscopic cracks and pores for sealing the aggregate pellets. This substantially reduces the asphalt absorption into the aggregate pellets to a value of 2% or less. Where the pellets are intended to be used with portland cement concrete it is desirable to render the pellets hydrophobic by the incorporation in the pellet mix and/or on the pellet surface a suitable hydrophobic coating or material.
In the initial processing of the MSW ash, it is preferred to handle the bottom ash component separately from the fly ash component although it is within the scope of the invention to treat the bottom and fly ash components as combined. A facility for making aggregate pellets may be located in proximity to the incineration installation and in proximity, if possible, to a bypass disposal site. The bottom ash can be delivered to the facility in sealed bed, watertight, and covered dump trucks. For inventory control, the incoming trucks can be weighed upon arrival, and proceed to an unloading area. The bottom ash is then processed through a gross de-lumper for removing large oversized and unprocessable lumps and onto one or more scalping screens which also remove oversized non-crushable objects such as 1" or larger in size. From the scalping screen the initial processed bottom ash may be conveyed directly to a processing area, or if necessary, it can be placed in stockpile storage, such as in an ash storage hall using a radial stacker.
The relatively dry fly ash fraction, that is fly ash or fly ash combined with spent lime, can be conveyed to the facility in dry bulk pneumatic tanker trucks. On arrival, the trucks may be weighed and unloaded pneumatically into a dry storage silo. It is understood that state of the art emission controls should be used for handling the fly ash, such as to those standards and equipment presently used by the coal fly ash and cement industries.
In the processing of the fly ash, at least the bottom ash component is processed to reduce it to a maximum size as from +4 to +8 mesh, and to remove a substantial portion of the magnetic fraction in the form of iron and magnetic ferric oxides (Fe 2 O 3 ). It is preferred that not more than 10% by weight of the final aggregate product should be iron expressed as ferrous oxide. The amount of iron present may be controlled by carefully removing, by magnetic separation, the magnetic iron fraction to the point where the remaining magnetic iron fraction is negligible, while the product is crushed and/or screened to a size where it may be readily blended and mixed, preferably not exceeding 4-mesh in size. Of course, some portion of the iron content can come into the mix as part of the portland cement or coal ash, and this should be recognized as a possible source of iron contamination.
Tests have shown that the RCRA priority metals are present in higher concentrations and leach more quickly from the fly ash fraction. The fly ash fraction may be treated by fixation separately from that of the bottom ash fraction, with the resultant substantial savings in the quantity of alkali silicates required for treatment, preferably potassium silicate. However, in order to provide assurance as to the environmental adequacy of such process, a procedure should be initiated whereby the metals fraction of the bottom ash is carefully monitored to assure that, at all times, it remains substantially free of such priority heavy metals as would require separate fixation or fixation combined with the fly ash.
If only the fly ash component is to receive chemical fixation, which is preferred, this fraction, in suitable proportion to the final mix, is added to a mixer, and a heavy metal fixation agent is added together with a required quantity of water to provide a desired consistency. The water component may approximate 80-100 lbs/ton of ash. After a short period of mixing and blending with the fixation agent to contact the particles to render inert the heavy metals (usually two to five minutes), the bottom ash fraction is added along with the remaining water to provide a fixed or constant moisture, which may be in the order of 15-25%, according to the mix. For proper utilization it is desired that the proportions of the processed bottom ash fines and treated AQCS fly ash be approximately in proportion to the generated quantities of each of these by-products by the burn facility. Unless otherwise identified, all percentages given herein are by weight.
The re-combined fly and bottom ash are fed through a pin mixer in which cementitious agents in the form of portland cement, lime, and/or coal fly ash are blended. At this point, other pozzolanic agents may be added such as silica fume. Further, where desired, a non-swelling clay in the form of kaolin may be added at a rate such as 1% of the mix. Also, water-reducing agents and hydrophilic materials may be added. A surfactant may be added to reduce water demands, and to help wet the fly ash, and the mixed material is then applied to a conventional pan pelletizer for pelletizing.
Thereafter, it is desirable to apply specific surface coatings corresponding to the desired characteristic of the cured pellet. Asphalt absorption in the pellets can be substantially reduced such as to 2% or less by applying a fine mesh quick lime coating to the green pellets, for example, by a drum mixer, so that the quick lime collects on the surface and penetrates the microscopic pores. Thereafter the coating is subjected to a fine water spray for hydrolyzing the calcium oxide, causing it to expand into the microscopic pores, effectively sealing the pellet. The excess calcium oxide resides on the surface and cooperates as an anti-stripping agent in an asphalt mix.
An alternative or supplemental procedure for reducing asphalt absorption is that of blending a glycol compound into the mixture prior to pelletizing. For example, ethylene glycol repels asphalt and therefore may be used as an inherent part of the mixture, with or without the lime coating heretofore described.
Where the pellet is to be used as a concrete aggregate, it may be desirable to coat the green pellet with a cement/clay blend to form a dense hard coating. At the same time, the surface may be coated with a hydrophobic powder, such as calcium stearate or a liquid mix sold by Master Builder Technologies of Cleveland, Ohio as Rheomix No. 235. Further, Mix 235 may be added at the rate of 1/10 to 1% per 100 pounds of portland cement used in the pozzolan prior to pan pelletizing.
Potassium silicate is preferred as a fixative agent for heavy metals, even though sodium silicate may be obtained at lower cost, since sodium reacts with sulfate in concrete mixes to form expansive compounds. However, in appropriate instances, sodium silicate may be used. A suitable and preferred potassium silicate fixative consists of Mix K-20 sold by Lopat Industries, Inc. of Wanamassa, N.J. 07712, and described in U.S. Pat. No. 4,687,373.
The product resulting from the process of this invention quickly air hardens and obtains substantial compressive strengths within twenty-four hours and within forty-eight hours. It is important that the product quickly obtain early compressive strength to permit immediate handling and early utilization, within two days of manufacture, if desired. Utilizing the process of this invention, 2-inch cubes have 24-hour compressive strengths of 1,800 psi or more and 48-hour compressive strengths of 3,000 psi or more. The addition of 1 to 5% calcium hydroxide, in the mix, also improves the one-day strength and further reduces asphalt absorption.
Where the products are coated, as described, absorption as determined by ASTM-D-2041 does not exceed 3.5% and preferably does not exceed 2.0%, calculated as asphalt absorption. The sulfate soundness does not exceed the requirements as tested by ASTM-C-88 and the loss by abrasion and impact does not exceed 40% when tested according to ASTM procedure C-535 in the Los Angeles abrasion and impact machine test. Additionally, the product is resistant to freezing and thawing as defined by ASTM-C-666 and by AASHTO designation T-103. The amount of clay lumps and friable particles does not exceed 2% and therefore meets the requirements of ASTM-C-142 and the friable requirements of ASTM-C-331.
In addition to the mechanical and physical requirements, the aggregate does not exceed 10% and preferably 8%, by weight, of iron expressed as ferric oxide (Fe 2 O 3 ). Most importantly, when ground to minus 100 mesh and tested under the TCLP test procedure as defined above, and as outlined by the U.S. EPA in document SW-846. The aggregate meets the defined 1990 federal drinking water standards for the eight RCRA priority metals, and therefore substantially exceeds the requirements for aggregates in asphaltic and portland cement concrete mixes.
It is accordingly an important object of this invention to provide a pelletized asphaltic or portland cement concrete aggregate which meets the physical and mechanical requirements for such aggregates, having as its principal ingredient processed ash residue from the incineration of municipal solid wastes, in which the heavy metal components are converted to inert and essentially nonleachable metal silicates so as to meet current 1990 federal drinking water standards for RCRA priority metals as set forth above.
Another object and advantage of the invention is the provision of an aggregate and method for making the same in which a specific surface sealing coating is applied to enhance the use of the pellet in asphaltic or portland cement concrete mixes.
A further important object of the invention is the provision of a method of utilizing municipal solid waste ash in the manufacture of an acceptable synthetic aggregate, as outlined above.
A still further object of the invention resides in the provision of a synthetic pelletized aggregate or a cold bonded pellet and the method of making the same, in which the pellet is formed with a sealing coating on an outer surface.
These and other objects and advantages of the invention will be apparent from the following description, the accompanying drawings and the appended claims.
BRIEF DESCRIPTION OF ACCOMPANYING DRAWING
The figure of the drawing represents a diagrammatic flow chart showing the preferred practice of the method of the invention in the handling and treatment of municipal solid waste ash.
DESCRIPTION OF PREFERRED EMBODIMENTS
As described above, the AQCS fly ash fraction is received, at the treatment facility, preferably separate from and stored separately of the bottom ash fraction. Referring first to the bottom ash fraction which represents by mass and by weight, the substantial bulk of MSW ash, it is delivered from a furnace 10, which may be a mass burning furnace in the manner previously described, and unloaded in a holding area 11. At this point it may be picked up by suitable handling equipment, such as front end loaders, and applied to a first screen separation in the form of a grizzly screen 12. It is assumed at this point that the bottom ash in the holding area 11 has been grossly classified so as to remove therefrom the over-sized and non-burnable components or unburned components, which components may be bypassed to landfill, preferably prior to transporting the bottom ash to the aggregate processing facility.
The grizzly or Trommel rotary screen 12, such as for example manufactured by Amadas Industries of Suffolk, Va., may remove everything over 2.0 inches to an oversize bin 13, for bypass disposal, passing -2.0 inches to a mechanical delumper 15. In the delumper 15, the agglomerated ash lumps which can be broken down by impact are broken down, and the output is delivered to a second screen 18, which, for example, may separate the over 1.0-inch material to an oversize bin 19, and the 1.0-inch and under material may be passed to a storage mound 20 for further processing. It will therefore be seen that the initial processing from the unloading area 11 to the storage mound 20 has, for its purpose, the removal of the uncrushable objects in excess of 1.0 inch and the crushing and reduction of clinkers and ash conglomerates to a more usable state. At this time, it is desirable to begin a multiple stage iron particle and ferrous iron magnetic removal. Excessive iron component in the mix and in the end product, in time, oxidizes and expands, causing staining and physical disruption in portland cement concrete mixes.
The initial stage of magnetic removal is preferably by a magnetic belt separator 22 where the major portion of the magnetic iron, in quantity, including substantially all of the larger pieces, are removed from the stream and separated to a ferrous bin 23. At this point, the material passing the first ferrous magnetic separation may be applied to a three-deck screen 30 providing three separation fractions, the coarsest and intermediate fractions being approximately 1" and 3/8" and the final fraction being no coarser than from 4 to 8-mesh, preferably in the 8-mesh region.
The two cuts from such a three-deck screen 30 are applied respectively to crushers 33 and 34 for further reductions and to secondary screens 36 and 37 respectively. The oversize from screen 36 may be bypassed to crusher 34 while the oversize from screen 37 may be bypassed to a final ferrous and oversize bin 40. The materials passing through the respective screens 36 and 37 are joined with the materials passing the three-deck screen 30 and represent a processed bottom ash of reasonable uniform consistency as to size. The common output of the screens at the junction region 42 is typically as set out in Table 4.
TABLE 4__________________________________________________________________________Composite of Representative Mass-Burn Bottom AshMoisture 19.5% ph - 10.5Size Net Wt. % of Total PerCent Retained PerCent Passing Non-Fe Ferrous % Fe__________________________________________________________________________+3/4" 435.5 5.5 5.5 100.0 340.9 100.6 22.83/4"-3/8" 1,459.0 18.3 23.8 94.5 937.8 359.6 27.73/8"-No. 4 1,676.7 21.0 44.8 76.2 1,427.5 351.4 19.8No. 4-No. 16 1,437.8 18.0 62.8 55.2 1,090.2 369.2 25.3No. 16 2,964.7 37.2__________________________________________________________________________
The screened and sized bottom ash is then applied to further processing by a pair of series-connected magnetic separator drums 44 and 45. The magnetic fraction is collected through a line 46 to a further ferrous storage bin 47. At this point, the processed bottom ash should not have more than 8% iron, most of which will probably be non-magnetic ferrous oxide, and is now in a condition in which it is ready for further processing with the fly ash fraction.
The decrease in iron oxide contents represents, typically, about a 60% decrease beginning from an average of approximately 20% Fe content, to 8% or less after processing, expressed as ferrous oxide. The incoming percentages of unburned ferric metals will, of course, vary, but the ash processing in accordance with this invention should reduce this component to approximately 8% or less of the mixture of the fly and bottom ash.
The AQCS fly ash, usually further including an excess of spent lime, is withdrawn from the fly ash storage area 50, which may be dry storage bins, by pneumatic conveyor to a surge hopper 51. Since the fly ash fraction may contain the higher concentration of the RCRA priority heavy metals, as previously identified, at least the fly ash fraction is then subject to treatment with a fixation agent in a paddle, pug-type, or other suitable mixer 52. As previously described, the chemical fixation process includes an agent which, preferably, includes a potassium silicate product 55 which is added to the AQCS fly ash fraction in the mixer 52, together with a necessary quantity of water such as to provide a moisture content of approximately 18%, for example.
As a further example, at this stage, the water component may approximate 80-100 lbs. per ton of fly ash during the fixation step, and the K-20 Agent 55 may be applied at the rate of one-half gallon per ton of fly ash. Heavy metal fixation is almost instantaneous with contact with the ash particles, and the charge of AQCS fly ash in the mixer 52 may be vigorously agitated from two to five minutes in order to assure complete fixation.
The mixer 52 may now be filled with the processed bottom ash collected from the magnetic separator drums 44 and 45 in a surge hopper 57, again with suitable additional water to maintain the desired moisture content. The ratio of processed bottom ash component to fly ash component may be on the order of from 3:1 to 5:1, the intent being to consume and utilize both the bottom and fly ash fractions in their entirety as they become available through the processing.
At this time, it may be desirable, optionally, to add further silicates to chemically fix the bottom ash. It may also be desireable to add a portion of the coal fly ash 58 as part of the mix and, if further desired, a quantity of silica fume (not shown), for mixing and blending and to provide final fixation of the heavy metals.
The mixed, blended, and stabilized combined ash product from the mixer 52 is then transferred to a pin mixer 60 for final processing and for the addition of the major cementitious and pozzolanic components as well as additional water, again as required to maintain a constant moisture content. The pin mixer may be of the kind manufactured and sold by Ferro-Tech of Wyandotte, Mich. 48192 under the trade name Turbulator.
The pin mixer 60 is a high efficiency mixer and is the preferred place where the cementitious materials for the purpose of manufacturing pellets are added. Cementitious material includes portland cement 62 and preferably includes Class C coal fly ash 63. The coal fly ash may be either cementitious Class C or pozzolanic Class F as defined in ASTM-C-618. Class C is preferred, in which case substantially less portland cement can be used as compared to mixes where Class F fly ash is employed, but either may be used with an appropriate quantity of cement, recognizing that Class F fly ash is not hydraulic (self-setting). Where Class F fly ash is used, it may be desirable to add additional lime in the form of calcium hydroxide. As previously noted, 1-5% calcium hydroxide may also be used in the mix to increase the compressive strength and to reduce asphalt absorption.
As an example, the cement component may be from less than 10% to greater than 16% of the mix. Where the cement component is 16%, then Class C fly ash may constitute 22% by weight of the mix. Where 10% cement is used, then Class C fly ash may, typically, constitute about 35% of the mix.
Alternatively, and as another example, where Class F fly ash has been used, it has been found that 20% Type I portland cement and 5% lime provides good results. Again, the cementitious constituents may be varied within the scope of the invention such as to provide a quick setting capability with 48-hour strength, in 2-inch test cubes, of about 3,000 psi or more. In all of these mixes silica fume may be added, such as at a 1% rate.
At this point, a surfactant 64 may be added to reduce the amount of water required. A suitable surfactant may be Amphosol CG (Amphoteric) which is a coco amido betiane which is manufactured by Stepan Chemical Company, Northfield, Ill. 60093, and an anionic Triton GR-7M, a dioctyl sodium sulfosuccinate, manufactured by Union Carbide Company. A nonionic surfactant such as Tritan N-101, nonylpheonoxy polyethoxy ethanol, manufactured by Union Carbide Company, may be further added. These surfactants may be added at the rate of 0.0010% of the total mix. Also, at this point, a hydrophobic agent 65 to be added into the mix also where the product is to be used as an asphaltic aggregate, an asphalt repelling glycol agent 66 may be added such as ethylene glycol at the rate of 1 gal./ton of mix. This has been found to be effective in substantially reducing asphalt absorption since ethylene glycol repels asphalt.
Hydrophobic coatings may be applied by adding hydrophobic materials both to the mix and to the green pellets after pelletizing. One such hydrophobic material which repels water is calcium stearate which is in powder form, and may be added directly to the mix in the pin mixer. Another such hydrophobic agent which repels water is Rheomix No. 253 which is in liquid form, and may advantageously be added to the water fraction or component prior to adding the water to the mix. These hydrophobic agents facilitate reduced water absorption in portland cement concrete mixes.
The content of the mixer 60 is applied to a pan pelletizer 70 which may be a disc-type pelletizer as manufactured by Ferro-Tech, previously identified.
The output of the pelletizer 70 comprising green (uncured) pellets of from about 1/4" to 158 " in diameter, and the green pellets may be cured as they are or they may be applied to a further mixer, such as the drum mixer 72, for coating.
Where the pellet is intended for use as an asphaltic aggregate, it is helpful to seal the microscopic pores in the pellet, which would otherwise increase asphaltic absorption, by coating the particles in the mixer 72 with a thin surface layer of -200 mesh quick lime, and thereafter spraying the pellets with a fine mist of water to hydrolyze at least a portion of the lime, causing it to expand and harden into the microscopic pores, thereby sealing the pellet. The lime is advantageously available as an anti-stripping agent to help the asphalt bond with the aggregate. This lime on the surface may eliminate the need for an anti-stripping agent in the asphaltic mix.
Other coatings may be applied to the green pellets, depending on ultimate use. For use in portland cement concrete mixes, it may be desirable to coat the pellets with a hard hydrophobic coating. A cement/clay blend may be added and hydrolyzed to form a dense hard coating. Also as previously identified, calcium stearate,. or Rheomix No. 253 may be added to provide a hydrophobic coating prior to curing and storing. Again, since calcium stearate is dry, it may be applied in dry form to the exterior surface and hydrolyzed while the liquid Rheomix material may be added by spraying.
In the selection of the cementitious and pozzolanic materials as described above, care must be taken to assure that unwanted RCRA priority metals are not inadvertently introduced in non-treated components, at either the mixer 52 or the mixer 60. Normally, coal fly ash, the by-product from burning pulverized coal in power plants, either Class C or Class F, is not a significant source of metals. However, it has been discovered that portland cement as delivered, may itself contain an excess of chromium, apparently due to the process of manufacture of the cement which, in the synthetic aggregate, may push the leachable chromium content above the standard and therefore should be closely monitored. It has been found that sulfate soundness has been maintained without the need for using Type II portland cement in the mix. It also should be recognized that some chromium content can find its way into the mix through the fly ash and silica fume which could cumulatively contribute to a higher leachable chromium element, but certain grades of Type I and Type II cement possible major contributor, and should be monitored as previously noted.
Also, in any utilization of the process of this invention in which the bottom ash is not treated with a fixative, the bottom ash should be monitored, preferably after processing and magnetic separation, at the hopper 57, for any leachable quantities of the RCRA priority metals as well as for any detectable dioxins or furans.
The following examples of mixes have produced good results:
______________________________________100 Tons in Mix______________________________________Mix No. 1MSW ash 61%Type II cement 16%Class C fly ash 22%Silica fume 1%Lopat* (1/2 gal. = 5#) 1/2 gal./ton of MSW ashWater 22%Mix No. 2MSW ash 54%Type I cement 10%Class C fly ash 35%Kaolin 1%Lopat 1/2 gal./ton of MSW ashWater 18%Surfactant 0.0010%______________________________________ *Lopat 0.0025% per lbs., tons, etc.
In the practice of this process, typically, a facility may produce about 260 tons of ash per day, 200 of which will be gross bottom ash, about 40 of which will be fly ash, and 20 of which will be spent lime combined with the fly ash. Of this, approximately 83% should be capable of processing into aggregate, approximately 12% recovered as ferrous metals, 1% recovered as non-ferrous metals, and approximately 4% sent to bypass disposal. These percentages, however, will vary depending upon the quantity of oversize bottom ash which must be removed.
The chemical composition of the synthetic aggregate produced from combined MSW ash has been determined to be as follows in Table 5.
TABLE 5______________________________________TOTALS CONCENTRATIONS OFSYNTHETIC AGGREGATE PRODUCEDFROM MSW COMBINED ASHProcedure: ASTM, Part 05.05, Method D4326-84 ASTM, Part 05.05, Method 3683 for Lead, Zinc, and CopperResults: Results are reported in weight percent (Wt. %), on a dry basis. Elements are extrapolated to the oxide form to express results as required in ASTMC114. Chemically fixated metals are in fact in the silicate form, but not expressed as such in this Table.Parameter Sample 1 Sample 2 Average______________________________________Silica, SiO.sub.2 32.45 32.43 32.44Alumina, Al.sub.2 O.sub.3 10.70 11.39 11.05Titania, TiO.sub.2 0.82 0.80 0.81Ferric Oxide, Fe.sub.2 O.sub.3 5.95 5.53 5.74Calcium Oxide, CaO 29.02 29.76 29.39Magnesia, MgO 2.38 2.40 2.39Potassium Oxide, K.sub.2 O 0.81 0.83 0.82Sodium Oxide, Na.sub.2 O 2.52 2.66 2.59Sulfur Trioxide, SO.sub.3 2.54 2.56 2.55Phosphorus Pentoxide, P.sub.2 O.sub.5 0.52 0.51 0.52Cupric Oxide, CuO 0.11 0.07 0.09Lead Oxide, PbO 0.16 0.09 0.13Zinc Oxide, ZnO 0.25 0.24 0.25Loss on Ignition @ 750° C. 9.74 9.67 9.71______________________________________
In a typical example, the results of the totals of TCLP leaching before and after chemical fixation of a blend of top and bottom ash are set forth below in Table 6. In Table 6, the gross metallic amounts are first identified prior to fixation, and then the TCLP extraction fluid No. 2 leach results are provided following fixation in accordance with the process of this invention, both before and after fixation.
TABLE 6______________________________________MSW Ash Before Chemical Fixation Haz/Solid 1990 Federal Total TCLP Waste Drinking Water Comp Leach Limits StandardsParameter (mg/kg) (mg/l) (mg/l) (mg/l)______________________________________Arsenic 44 <0.002 5.0 0.05Barium 435 3.0 100.0 1.00Cadmium 38 0.11 1.0 0.01Chromium 52 0.024 5.0 0.10Mercury 6.5 0.006 0.2 0.002Lead 1167 5.6 5.0 0.05Selenium 0.65 <0.005 1.0 0.01Silver 10.07 <0.01 5.0 0.05______________________________________Aggregate After Chemical Fixation(Aggregate Crushed to Minus 100 Mesh) 1990 Federal Total TCLP Haz./Solid Drinking Water Comp Leach Waste StandardsParameter (mg/kg) (mg/l) (mg/l) (mg/l)______________________________________Arsenic 25 <0.05 5.0 0.05Barium 700 0.55 100.0 1.00Cadmium 17 0.0002 1.0 0.01Chromium 57 0.06 5.0 0.10Mercury 4.3 0.0003 0.2 0.002Lead 570 0.0002 5.0 0.05Selenium <0.25 <0.0005 1.0 0.01Silver 7.6 <0.01 5.0 0.05______________________________________
In conclusion, it will be seen that this invention provides a method of making an economically useful commercial synthetic aggregate utilizing a substantial portion of MSW ash, which product is environmentally safe as defined by existing EPA standards. In some instances, it may be useful to withdraw the mixed and blended material from the pin mixer without pelletizing, for use as a "sand" filler for both asphaltic and portland cement concrete mixes. This material has the major properties and advantages of the pellets described above particularly including the leach ability standards, as set out in Table 6. The material from the pin mixer usually is reduced to a size of about 20 mesh and, accordingly, without further treatment is useful as a filler sand, as described.
While the method and product herein described constitute preferred embodiments of the invention, it is to be understood that the invention is not limited to this precise method and product, and that changes may be made therein without departing from the scope of the invention which is defined in the appended claims.
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Municipal solid waste ash is utilized in the manufacture of an aggregate and is processed to form a cold bonded pellet which, when tested by means of TCLP leaching extraction tests using TCLP No. 2 extraction fluid, does not exceed the 1990 limits for the RCRA priority heavy metals. The pellets may be surface coated with defined agents to seal the pellet or to provide properties which enhance the use of the pellet in either asphaltic or cement concrete mixes. A method of utilizing MSW ash includes the steps of collecting the bottom ash and fly ash components, processing the bottom ash component to remove unprocessible material and crushing the crushable component to a desired size, magnetically separating the magnetic material from at least the processed bottom ash component, treating at least the fly ash component of the ash with alkali silicate to fix the heavy metals, and utilizing the processed ash such as by adding cement or other binders in a mix to form pellets having an early strength sufficient to permit handling after 24 hours. Pellets may be treated with selective components and coatings to enhance the pellet's use as an aggregate in asphaltic or cement concrete mixes.
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BACKGROUND OF THE INVENTION
A presser bar in a sewing machine transmits pressure to a presser foot at one end of the bar, and the foot transmits this pressure to the work, or material to be sewn. At times during the sewing operation, for example when one stitching operation has been finished and the work is being removed to be replaced by new material, the presser bar is moved longitudinally away (which means normally upward) from the work by means of a lever. When the operator desires to reapply pressure to the work or to begin sewing on new work, the lever is actuated in the reverse direction, and force is transmitted from a biasing spring to move the presser bar longitudinally into engagement with the work then in position to be sewn.
It is desirable that the force of the spring act as nearly precisely axially along the presser bar as is possible without exerting any side forces that would tend to pivot the presser bar about some axis more or less perpendicular to the longitudinal direction of the bar.
One way of applying pressure in the desired longitudinal direction is to place a compression spring between the upper end of the presser bar and a fixed member. Unless the diameter of the spring is large relative its length, a compression spring has a tendency to bend, displacing its central coils from alignment with coils at the ends. In a sewing machine, there is not enough space to have a very large diameter spring supply the force for the presser bar.
It is also desirable to utilize a compression spring that is relatively long, but this only exacerbates the lateral displacement of central coils of the spring. In order to limit such displacement, it has been the practice to enclose the compression spring in a hollow end of the presser bar of slightly larger inside diameter than the outside diameter of the spring. A cylinder extending into the mouth of the hollow end holds the spring in place. Although this does not entirely prevent the undesired lateral displacement, it limits such movement of the central coils and it also prevents the spring from becoming completely disengaged from either the end of the presser bar or the fixed member. However, the spring can still flex laterally enough to rub on the inner wall of the hollow tubular member, which is undesirable. In addition, the presser bar can also engage the outer surface of the cylinder due to some sidewise pressure applied to the presser foot. These limitations on the satisfactory movement of the spring and the pressor bar result in a hysteresis effect, which is also known as "stick slip".
The use of an extension spring to apply downward force to a presser bar to bias it against the work in a sewing machine has been suggested by Rodman in U.S. Pat. No. 823,442, by Feigel in U.S. Pat. No. 1,749,529, by Niekrawietz in U.S. Pat. No. 3,282,237, and by Giesselmann et al in U.S. Pat. No. 4,044,701. However, in each of those patents the force of the extension spring was not applied directly along the axis of the presser bar but was applied to one side of the axis, thereby producing a mechanical moment resulting in hysteresis.
SUMMARY OF THE INVENTION
One of the objects of the present invention is to overcome the hysteresis, or stick slip, effect on a sewing machine presser bar.
A further object is to avoid the problems caused by the use of a long, slender compression spring to apply axial force to one end of a presser bar.
A further object is to provide a simplified spring bias structure that can be manufactured easily and inexpensively and yet will provide force directed along the axis of the presser bar.
In accordance with the present invention, a simple extension spring is threaded onto two members, one of which is attached to an upper part of the presser bar and the other of which is held down by a bracket. Both the bracket and the member attached to the upper end of the spring are mounted on a second bracket to be attached to the arm of the sewing machine as a unit. A lever is also mounted on the second bracket to drive a connecting member that pushes the first member up, and thereby extends the spring, in order to raise the presser bar and presser foot. The second bracket also has bushing means mounted on it to constrain the motion of the presser bar so that it can move only longitudinally.
The amount of pressure exerted by the presser foot on the work can be controlled by controlling the distance between the first and second members. This distance, in turn, can be controlled by a cam mounted on the second bracket and applying force to the first bracket by means of a cam follower mounted on the first bracket.
Force to lift the presser bar may be transmitted from the lever by means of another cam controlled by the lever and acting on a second cam follower attached to the link that forces the first member up when the lever is pivoted to raise the presser foot.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded, perspective view of a presser bar actuating mechanism incorporating the present invention;
FIG. 2 is a front view of the head end of a sewing machine incorporating the mechanism of FIG. 1;
FIG. 3 is a side view of the head end of the machine shown in FIG. 2, partly in cross section to illustrate the presser bar in the position occupied when the machine is operating;
FIG. 4 is a view corresponding to FIG. 3 but with the presser bar and presser foot raised.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The exploded perspective view in FIG. 1 shows the components associated with a presser bar 11, which is arranged to be resiliently biased by a helical extension presser bar spring 12 that surrounds the upper part of the presser bar. The spring 12 is quite simple to manufacture, since it has plain ends without hooks or eyes. One configuration that has proved to be satisfactory consists of twenty-two closely wound coils of ASTM A-228 music steel spring wire wound so that the spring has an inner diameter of 10.2 mm. The bar 11 is generally cylindrical with a round cross section except at its lowermost end which has one side milled away. A standard presser foot 13 is attached by means of a pin 14 to a clamp 16, which is connected, in turn, to the lower end of the presser bar 11 by means of a screw 17.
A presser bar guide bracket 18 is attached at or near the upper end of the presser bar 11 by means of a set screw 19. The presser bar guide bracket 18 is, in this embodiment, in the form of a block having a cylindrical channel 21 into which the upper end of the presser bar 11 extends. Surrounding the lower end of the channel 21 in the presser bar guide bracket 18 is an externally threaded member 22 that has a diameter and thread pitch such that the upper end of the spring 12 can be threaded onto it with some effort. A dog 23 extends from one face 24 of the block-shaped presser bar guide bracket 18. This presser bar guide bracket may be considered a first holding means for the helical extension spring 12.
A second holding means to hold the other end of the helical extension spring 12 comprises a presser bar spring tensioner 26 that consists of a block portion 27 and a second externally threaded member 28 extending upwardly from the upper surface 29 of the block 27 and threaded into the lower end of the helical spring 13. When a spring having twenty-two turns is used, three turns at each end may be threaded onto the members 22 and 28 but more or less turns can be threaded on to adjust the tension approximately. Another cylindrical channel 31 extends through the helically grooved member 28 and the block 27 and is of substantially the same cross sectional size and shape as the presser bar 11 but with just enough clearance so that the bar can move smoothly in a longitudinal direction in the channel 31. Two lugs 32 and 33 extend from opposite sides of the block 27 and fit into notches 34 and 36 at the lower ends of two arms 37 and 38, respectively of a presser bar pressure regulating bracket 39. This bracket is made of sheet metal in the present embodiment, and the arms 37 and 38 are bent so as to be perpendicular to a central portion 41 and substantially parallel to each other. A support member 42 is bent from the central portion 41 in a direction opposite from that in which the arms 37 and 38 are bent, and a base 43 is bent outwardly perpendicularly to the support 42. This base includes apertures 44 and 46 into which a stud 47 and a cam follower stud 48, respectively, are riveted.
The presser bar pressure regulating bracket 39 is mounted on a presser bar mounting bracket 49. The latter is also a sheet metal structure in this embodiment and comprises a central member 51 with two support members 52 and 53 that are bent perpendicularly to the central member 51 and substantially at opposite ends thereof. A base 54 having an aperture 56 is bent outwardly from the end of the support 52, and a base 57 having an aperture 58 is bent outwardly from the support 53. A spacer 59 is bent from the member 51 in the opposite direction from the supports 52 and 53 and has a guide member 61 with a threaded opening 62 and an elongated slot 63 in it. The length of the spacer 59, that is, the distance from the surface of the member 51 visible in FIG. 1 to the visible surface of the guide member 61, is substantially equal to that of the support 42. This allows the rear surface, i.e. the surface not visible in FIG. 1, of the base 43 to slide on the front, or visible, surface of the guide member 61 and the rear surface of the central portion 41 of the pressure regulating bracket 39 to slide on the front surface of the mounting bracket 49. The stud 47 and the cam follower stud 48 guided by the groove 63 constrain the presser bar pressure regulating bracket 39 to move only in one direction with respect to the presser bar mounting bracket 49 and are held in place by retaining rings 60 and 65. Another stud 64 riveted into an aperture 66 in the central member 41 of the presser bar pressure regulating bracket 49 extends into an elongated slot 67 in the member 51 of the presser bar mounting bracket 49 as a further aid in constraining the presser bar pressure regulating bracket 39 to move only back and forth in one direction and not to rotate with respect to the presser bar mounting bracket 53. A retaining ring 70 holds the stud 64 in the slot.
The presser bar spring 12 tends to pull the spring tensioner 26 and the guide bracket 18 as close together as possible. The ultimate degree of proximity would be obtained if the coils of the spring 12 could be in contact with each other, which is the condition in which the spring is wound. However, the mounting bracket 49 holds the guide bracket 18 and the spring tensioner 26 farther apart than that. The shouldered screw 19 extends through an elongated slot 67 near the upper end of the mounting bracket 49. The lowermost position of the presser bar guide bracket 18 is obtained when the shouldered screw 19 comes in contact with the lower end of the slot 67. The position of the presser bar spring tensioner 26 is determined by the position of the presser bar pressure regulating bracket 39, which, in turn, is controlled by a presser bar pressure regulating cam 68 acting on the cam follower stud 48.
The cam 68 may be molded of any suitable material, such as ABS Cycolac "T" or Lustran 400, for example as part of a molded presser bar pressure regulating dial 69 attached by a central, shouldered screw 71 to the presser bar mounting bracket 49. The screw 71 is screwed into the threaded hole 62 in the bracket 49, and the cylindrical part of the screw 71 serves as an axle for the dial 69. The pressure regulating cam 68 has a plurality of detent recesses 72 that are engaged by the cam follower stud 48 to hold the dial 69 in any one of several specific positions. The general configuration of the cam 68 is such that each successive detent position, as the cam is rotated in the direction of the arrow 73, allows the cam follower stud to move closer to the axis of the shouldered screw 71. This, in turn, permits the presser bar pressure regulating bracket 39 to move upward with respect to the mounting bracket 49 as the studs 47, 48, and 64 move upward in the slots 63 and 70 in response to tension in the presser bar spring 12. The cam 68 has two stops 74 and 75 that limit the rotation of the dial to slightly less than 180°.
The setting of the dial 69 determines the amount of pressure applied to the work when the presser foot 13 is in its operative position. However, the pressure dial does not rotate far enough to allow the presser foot 13 to move entirely away from the work. Such movement of the presser foot is accomplished by means of a presser foot lever 76 pivotally mounted on a shouldered stud 77 riveted into an aperture 78 in the central member 51 of the presser bar mounting bracket 49. The lever 76 has a cam surface 79 that includes a detent recess 81 and an additional portion 82 beyond the detent. A cam follower stud 83 riveted into an aperture 84 in a presser bar lifter lever link 86 transmits the pivotal movement of the lever 76 into a longitudinal movement of the link 86. The latter has two elongated slots 87 and 88. The shouldered stud 77 extends through the slot 87 so that the link 86 is free to move longitudinally in response to engagement of the cam follower 83 on the cam surface 79. The shouldered screw 19 passes through the upper elongated slot 88. The slots 86 and 88 allow the presser foot 13 to ride over seams without lifting the link 86.
The lever 76 is shown in its normal, or operative, position, which is the position it occupies when the presser foot 13 is in engagement with the work. In this condition, the spring 12 pulls the link 86 downwardly by urging the shouldered screw 19 against the lowermost end of the slot 88 and pressing the uppermost end of the slot 87 against the shouldered screw 77.
When the presser foot 13 is to be raised from the work, the lever 76 is moved in the direction of an arrow 89. This causes the cam follower 83 to be lifted by the cam surface 79, which causes the link 86 to move upwardly. The link is prevented from pivoting or moving in any other direction than the up and down direction by the shouldered stud 77 and the shouldered screw 19, which engage the sides of the elongated slots 87 and 88, respectively. The link 86 transmits the upward motion of the cam follower 83 to the presser bar guide bracket 18 and thus lifts it, as well as the presser bar 11, upwardly away from the work. This stretches the presser bar spring 12, so that release of the lever 76 would allow the spring to pull the guide bracket 18 down until the shouldered screw 19 either reached the bottom of the elongated slot 67 or it reached the bottom of the elongated slot 88 and the top of the elongated slot 87 reached the shouldered rivet 77. Either of those conditions will limit the lowermost position of the presser bar guide bracket 18.
The presser bar 11 would not be adequately constrained by the spring tensioner 26 acting as a bushing. Therefore, a fixed bushing 91 is mounted on the presser bar mounting bracket 49. The bushing 91, in this embodiment, is a block with a channel 92 shaped to fit closely around the cylindrical presser bar 11 but with just enough clearance to allow the presser bar to slide smoothly therein. The bushing 91 is preferably molded of a material having a low coefficient of friction, such as Delrin 500 or Celcon M90-04, which is also a suitable material for the spring tensioner 26. The bushing 91 has two pins 93 and 94 extending from its rear surface 95 to fit into guide holes 96 and 97, respectively, in the mounting bracket 49. The bushing 91 also has an integrally molded side flange 98 with an aperture 99. The distance from the rear surface 95 of the bushing 91 to the rear surface 102 of the flange 98 is substantially equal to the height of the support member 52 from the visible surface of the central member 51 to the visible surface of the base 54. Furthermore, the aperture 99 is formed so as to be substantially directly aligned with the aperture 56 when the pins 93 and 94 are in the holes 96 and 97.
All of the units described to this point are mounted on a plate 103 to be attached as a preassembled structure to the arm of a sewing machine. The plate 103 has a rectangular opening 104 and a threaded hole 106 along side it. The rectangular opening 104 is shaped to fit the end 105 of the bushing 91, and the threaded hole 106 is located to be aligned with the apertures 56 and 91 to receive a machine screw 107 to hold one end of the mounting bracket 49 and the bushing 91 firmly in place on the plate 103. The other end of the bracket 49 is held in place by another machine screw 108 through the aperture 58 in the base 57 and screwed into a threaded hole 109 in the plate 103. Thus, only two screws 107 and 108 are needed to hold all of the parts in place on the plate 103. When these parts are so assembled, the dog 23 is in position to slide within a slot 111. The presser bar guide 18 of which the dog 23 is an integral part is machined of metal, and in order to minimize friction, the slot 111 is defined within an elongated border 112 of low-friction material, such as Delrin or Celcon, similar to the bushing 91 and the tensioner 26.
FIG. 2 shows the components of FIG. 1 assembled into a presser bar control system. As may be seen, the link 86 has a lower end 113 that is offset from the upper end 114. The latter is directly against one surface 116 of the mounting bracket 49, while the lower end 113 is spaced from the mounting bracket by a distance equal to the thickness of the lever 76 in the region of its axle, the shouldered rivet 77. The components are, for the most part, mounted in a head 117 at the end of an arm 118 of a sewing machine. The plate 103 is mounted in any suitable manner, and one of the parts of the mounting structure for the plate is a rod 119, only one end of which is shown in the drawing.
FIG. 3 not only shows an end view of the head 117, but also shows a standard 120 that supports the arm 118 (FIG. 2) the standard 120 extends upwardly from a bed 121, the upper surface of which is flat. A throat plate 122 and a feed dog 123 are mounted in the usual way in the bed 121.
In addition to the presser bar 11 and the apparatus to control its position, FIG. 3 also shows a needle bar 124 carrying a needle 126 at its lower end. The apparatus to actuate the needle bar 124 in its usual reciprocating motion is not part of the present invention and need not be described.
In FIG. 3, the lever 76 is in its operative position, that is, the position in which the presser foot 113 is in its lowest position, which is the low position with the foot in position to press work against the feed dog 123 of the machine. In this position, the shouldered screw 19 is against the lower end of the slot 88 in the link 86, and the link is thus pulled down by the spring 12 to force the cam follower 83 against the cam surface 79 of the lever 76.
FIG. 4 shows a fragment of the machine in FIG. 3 with the lever 76 in its inoperative, or raised, position. Due to pressure of the cam surface 79 against the cam follower 83, the link 86 has been forced upward, causing the presser bar guide bracket 18 to be raised, thereby lifting the presser bar 11. This provides space under the presser foot 13 to allow work 124 to be moved easily between the presser foot and the throat plate 122.
In FIG. 4, the position of the lever 76 shown in solid lines is such that the cam follower 83 rests in the detent recess 81. The pressure of the cam follower 83 against the detent surface will keep the lever 76 in this position until it is delibrately moved to another position, usually the position shown in FIG. 3. However, it is possible to move the lever 76 to a still higher position, illustrated in broken lines, in which the section 82 of the cam surface on the lever is in contact with the cam follower 83. Under such circumstances, the presser foot 13 is lifted to a still higher position, as illustrated in broken lines, to allow a somewhat thicker stack of material to be placed between it and the throat plate 122. The cam surface shown in FIG. 4 does not have a detent recess to hold the lever 76 in its most extreme position illustrated in broken lines, although a detent recess could be provided for that purpose if necessary. However, it is considered that the lever 76 would not often have to be raised to this extreme position and that merely raising it sufficiently to allow the follower 83 to drop into the detent recess 81 would normally be sufficient.
While this invention has been described in terms of a specific embodiment, it will be understood by those skilled in the art that modifications may be made therein within the true scope of the invention as defined by the following claims.
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A tension spring concentric with the presser bar pulls the presser foot down against the work. The spring is threaded onto two holders, each of which fits around the presser bar. The first holder is attached to the presser bar near its upper end but the second allows the presser bar to slide within it. The second holder is slidably attached to a bracket and controlled by a presser bar pressure regulating cam to slide up and down in the bracket and thereby change the tension in the spring to exert a controlled force on the presser foot. The first holder is also slidably mounted in the bracket, and is controlled by a lever that has a lifting cam linked to the first holder. When the lever is lifted, the first holder is lifted to raise the presser bar and presser foot away from the work. This extends the spring, which urges the presser foot back down against the work as soon as the lever is lowered.
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The present invention relates generally to locking systems particularly suitable for use in motor vehicles and more particularly to a driving mechanism for such locking systems operable to control locking of doors, tops and hoods of such motor vehicles.
A door locking system for motor vehicles is known from U.S. Pat. No. 3,243,216 wherein the system can be locked or unlocked in a conventional manner by means of a key or by an operating rod which ends in an actuating button at the vehicle door. This driving mechanism has a unidirectional electrical geared motor which also acts upon the operating rod by means of an eccentric drive device. The eccentric drive includes a driven member which is slidably supported on the operating rod and which is pressed by a spring against a fixed stop of the operating rod. An eccentric element of the eccentric drive mechanism moves the driven member and consequently the operating rod between a first position wherein the lock is in the locked condition and a second position in which the lock is unlocked, and vice versa.
The motor is connected by a control circuit to always effect rotation of the eccentric element through one half of a rotation. Since the driven member is supported for the operating rod to be slidable against the force of the spring, the door lock can be manually unlocked even if the eccentric drive is blocked which may, for example, occur due to failure of the system.
The geared motor of the known driving mechanism is only disconnected at the final position. However, this final position is not reached if the locking mechanism is blocked, for example by icing or due to failure. This may lead to destruction or damage of the drive motor or of the eccentric drive mechanism of this known device.
The present invention is directed toward improving driving mechanisms for locking arrangements of motor vehicles in such a manner that damage will not occur even during obstruction of the locking mechanism of the system.
SUMMARY OF THE INVENTION
Briefly, the present invention may be described as a locking system particularly suitable for a motor vehicle for use with a unidirectional electric motor comprising lock means movable between a locking and an unlocking position, a driven member coupled with said lock means, an eccentric drive element for engaging said driven member to move said lock means between said locking and unlocking position, motor means for rotatively driving said eccentric element, control circuit means including switch means responsive to the position of said lock means for controlling operation of said motor means, and elastic means interposed between said driven member and said eccentric drive element to permit said motor means to continue to rotatively drive said eccentric drive element when movement of said lock means is obstructed.
Thus, improvements are achieved according to the present invention in that a compensating arrangement is installed in the force transmission path between the eccentric element and the driven member, which driven member is usually slidably maintained within a guide frame. The compensating arrangement is effected in both sliding directions of the driven member and the motor means and/or the compensating arrangement is dimensioned in such a way that the motor means is capable of rotating the eccentric element even if the driven member or the lock means become obstructed.
As a result, the motor means can always rotate the eccentric element into a final position thereof even if the driven member is obstructed. In this final position, the motor means will be disconnected by the control circuit means.
In accordance with a more specific aspect of the invention, the driven member may be formed as a frame having two elastic compensating elements which are arranged opposite each other and spaced apart in the sliding direction of the driven member with the eccentric element engaging between these two compensating elements. The compensating elements may be formed as blocks of rubber or similar elastic material. However, in a preferred embodiment of the invention, compression springs which are supported at the driven member frame are provided. If necessary, sliding members may also be provided which are slidably guided at the frame in its sliding direction in order to reduce damage due to wear.
The driving mechanism is particularly suitable for use in the central locking system of a motor vehicle especially when each of the driving mechanisms is provided with a control switch by means of which the remaining driving mechanisms of the central locking system in the unlocking position of one of the driving mechanisms can also be controlled into the unlocking position. In this manner, if one of the locking devices of the motor vehicle locks is obstructed, it will be prevented that this lock will remain unlocked without being noticed when the central locking system is locked while the remaining locks are correctly locked. The control switch of the driving mechanism of that lock which remains unlocked in this case steers all remaining locks into the unlocked position which usually will not remain unnoticed by the operator of the vehicle.
As a result, an indication of a malfunction in the locking system will be provided if any one of the locking elements remains unlocked.
The compensating arrangement permits manual adjustment of the drive member of the eccentric drive mechanism independently from the position of the eccentric element and consequently the motor vehicle lock may also be unlocked or locked manually. The driving mechanism may be expanded in a simple manner to include a theft protection function will prevent manual unlocking of the lock. For this purpose, a second drive member may be coupled with the eccentric element which can be moved by the eccentric element transversely to its rotational axis along a guide device which is attached to the motor with this driven member mechanically blocking in a first position the unlocking mechanism which is to be manually actuated against manual activation and releases it in a second position. Advantageously, the final positions of the eccentric element are always rotated further by 90° against the angular positions which move the driven element into the first or the second position. In this way, the eccentric element can be held by means of a limit switch, when the theft protection is turned on, in an intermediate position in which driven members take up a dead center position of the sliding movement.
The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its use, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated and described a preferred embodiment of the invention.
DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a schematic sectional view showing a driving mechanism for the lock system of a motor vehicle door or other like elements of the vehicle, structured in accordance with the present invention; and
FIG. 2 is a circuit diagram for a central locking system for the motor vehicle which is structured utilizing the driving mechanism depicted in FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, the locking system of the present invention is provided with a driving mechanism in accordance with FIG. 1 which is formed with an essentially closed housing 1 having therein a frame 3 supported and guided for sliding movement. The frame 3 is rigidly connected with a rod 5 which projects beyond the housing 1. The rod 5 is connected to a locking element (not shown) of one of several locks of a motor vehicle which is to be controlled by operation of the invention, as will be more fully explained hereinafter. The locking system of the locking element may be manually locked or unlocked by means of a key or by manual actuation of a button such as that which may be provided on the door of a vehicle. A locking element of the locking system is unlocked when the rod 5 and the frame 3 are in the position shown in FIG. 1. When the rod 5 and the frame 3 are moved into a final position toward the bottom as viewed in FIG. 1, the locking element is brought to the locked position.
An eccentric cam 7 arranged within the housing 1 is mounted to be unidirectionally rotated in a direction indicated by the arrow 11. An electrical geared motor 9 which is flanged to the housing 1 is provided for driving the eccentric cam 7.
The eccentric cam 7 operates to engage a pair of sliding or movable plates 13 and 15 which are supported on the frame 3 in order to drive the frame 3 and the rod 5 between the unlocking position and the locking position of a respective locking element. The sliding plates 13, 15 are arranged on both sides of the eccentric cam 7 taken in the sliding direction of the frame 3 and they are themselves mounted so as to be movable relative to the frame 3 in the sliding direction of the frame 3.
The plates 13 and 15 are made slidably movable relative to the frame 3 by means of compression springs 17 and 19, respectively, interposed between the plates 13, 15 and the frame 3. The lengths of the paths of movement of the sliding plates 13, 15 are dimensioned in such a manner that the eccentric cam 7 can rotate against the pressure of the compression springs 17 and 19 past the sliding plates 13 or 15 even when the frame 3 is in the final position which has been reached always when the other sliding plate is acted upon. In addition, the force of the compression springs 17 and 19 as well as the driving power of the geared motor 9 are dimensioned in such a way that the eccentric cam 7 during normal operation can move the frame and the locking system connected therewith, while if the frame 3 or the locking system of the lock is obstructed, the eccentric cam 7 can rotate over the hindering sliding plate. In its stoppage position, the eccentric cam 7 is always rotated further by 90° against the angular position which it occupies when reaching the final position of the frame 3.
A blocking element 21 is also movably supported in the sliding direction of the frame 3 at the housing 1, the element 21 being coupled by means of a guide rod 23 with the eccentric cam 7. The eccentric cam 7 moves the blocking element 21 in the same direction with the frame 3 wherein, however, the lift of the blocking element 21 is greater than the lift of the frame 3. The blocking element 21 and the frame 3 reach the dead center positions which are located at the top or the bottom in FIG. 1 at the same angular position of the eccentric cam 7. On the blocking element 21, a projection 25 is installed which engages behind the frame 3 on the side which is located in the unlocking direction of the frame 3. This projection locks the frame 3 against manual shifting in the bottom dead center position which corresponds to the locking position of the lock.
The geared motor can be stopped in the locking dead center position if a theft protection circuit (not shown) of the motor vehicle is activated.
The driving mechanism is controlled by means of two switches 29 and 31, with the switch 29 being operated in dependence on the position of the rod 5 or a part fixedly connected with this rod, and with the switch 31 being operated in dependence on the position of the eccentric cam 7 or a part which is firmly connected therewith.
FIG. 2 shows details of a control circuit of a central locking system of a motor vehicle which is constructed with the driving mechanism according to FIG. 1. The switches 29 and 31 and the geared motors 9 which belong to the same driving mechanism are identified with similar reference characters. The driving mechanisms identified with the reference characters a and b drive the locking elements in the front doors of the vehicle which can be locked or unlocked manually by means of a key as well as also by means of actuating buttons in the doors. The driving mechanisms identified by reference characters utilizing reference letters c and d may be connected to close the rear doors of the vehicle which may also be manually locked by means of actuating buttons. The driving mechanism identified with e locks the trunk of the vehicle.
The motors 9 are connected in parallel always with one connection, at the one pole of a vehicle battery 33 whose other connection is connected in parallel with all center contacts of the switches 29. The other connection of the motors 9 is connected with the movable contact of the respectively assigned switches 31. The switches 31 are constructed as reversing switches wherein always the respective contacts are connected parallel with each other. The switches 31 are operated, for example, by means of a cam 34 in such a manner that they are switched over when the respective final position of the eccentric cam 7 has been reached. The switches 29a and 29b are also constructed as reversing switches. Their fixed contacts are connected with the fixed contacts of the assigned switches 31a and 31b in such a way that during switching over of the switches 29a or 29b the electrical circuit of the motors which are joined in parallel by means of the switch 31a or 31b which is waiting in the always other final position. In FIG. 2, the switches 29a and 29b are shown in the unlocking position. The unlocking position of the eccentric cam 7 corresponds to the position of the switches 31a-31e which is shown. When the switch 29a or 29b is switched over, all the motors 9a-9e are connected until the other final position is reached in which the switches 31a-31e change over into the position shown at the top in FIG. 2. In this position the locks are locked.
The switches 29c and d are shown as on-off switches which are closed in the unlocking position. They ensure that if the assigned driving mechanism is blocked, all driving mechanisms of the central locking system are again unlocked, even if they were already locked and this will give an indication of a malfunction.
In addition to the switches 29a-29e, a switch may be provided which is connected in parallel and which is actuated depending on acceleration and which unlocks during an accident any door which may be locked.
The switch 29c is constructed as a reversing switch actuated by means of a key--like switches 29a and 29b resp.,--except that this switch includes an electrically functionless switch position (indicated by dotted switch position). This functionless switch position is necessary to allow obstruction of the electromotively operated gear, if only the trunck remains locked and the doors are to be unlocked, when the car is in the repair shop, for example.
The switches 27, 29a-29e and 31a-31e may also be constructed as inexpensive sliding contacts.
While a specific embodiment of the invention has been shown and described in detail to illustrate the application of the inventive principles, it will be understood that the invention may be embodied otherwise without departing from such principles.
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In a locking system particularly suitable for a motor vehicle for use with unidirectional electrical motors, there is interposed between motors of the system and locking elements individually driven by said motors, a driving mechanism including a driven member coupled with each of the locking elements, an eccentric drive element engaging said driven member to move the locking elements between locking and unlocking positions, and elastic means interposed between the driven member and the eccentric drive element to permit the motors to continue to rotate the eccentric drive element when movement of any one of the locking elements is obstructed.
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FIELD OF THE INVENTION
The present invention broadly relates to the treatment of cancers in a patient, wherein such cancers are susceptible to treatment by co-administering to the patient S-(methylthio)-DL-homocysteine and a copper delivery agent.
BACKGROUND OF THE INVENTION
S-(Methylthio)-homocysteine (SMETH) is disclosed in Japanese Patent Publication Kokai No. 77 83710, Jul. 12, 1977 (C.A. 88:23393m). This publication, however, fails to recognize the potential therapeutic effects of SMETH, particularly its ability to function as a potent glutamine antagonist in cancer cells. Other glutamine antagonists which are effective as anti-cancer agents are natural antibiotics. These particularly include 6-diazo-5-oxo-norleucine, azaserine, and acivicin. These antibiotic compounds tend to be disadvantageous because they exhibit a low degree of biochemical specificity.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a pharmaceutical composition for the treatment of cancers susceptible to treatment therewith in animals and humans in u non-toxic manner.
Another object of the present invention is to provide an effective anti-cancer agent for treating cancers susceptible to treatment therewith, and a method for its delivery, which anti-cancer agent will function as a glutamine antagonist.
Yet another object of the present invention is to provide such an anti-cancer agent and method for its delivery, so that the same agent will exhibit a high degree of biochemical specificity.
Still another object of the present invention is to treat cancers susceptible to treatment with the pharmaceutical compositions herein provided based upon a new principle of binary cytotoxicity to tumor cells.
These and other objects are accomplished by providing a pharmaceutical composition for the treatment of cancers susceptible to treatment therewith, the composition comprising co-administering to a human or animal with a cancer susceptible to treatment (a) S-(methylthio)-DL-homocysteine (SMETH) or the L-enantiomorph; and (b) copper ion sequestered in a chelate functioning as a delivery agent for copper, in which an anti-cancer agent is formed by a complex of (a) and the copper of (b).
The present pharmaceutical compositions may be effective in treating many types of cancers susceptible to treatment therewith, including the treatment of ovarian cancer which has spread within the peritoneum.
The S-(methylthio)-DL-homocysteine can be utilized in its racemic form, or the L stereo isomeric form
The copper delivery agent can vary, and this agent delivers the copper as a non-toxic chelate. The copper can be delivered as a copper chelate of bis-thiosemicarbazones. More preferably, the copper is delivered as a non-toxic chelate of nitrilotriacetic acid (which is known to be effective as a copper delivery agent in humans).
The S-(methylthio)-DL-homocysteine (or its L-stereo isomeric form) and copper delivery agent can be administered intraveneously and intraparentally. The S-(methylthio)-DL-homocysteine (or its L-stereo isomeric form) and copper delivery agent can be administered, for example, as a saline solution, but the solution cannot contain sulphites or ascorbic acid, or other similar reducing agents.
The S-(methylthio)-DL-homocysteine (or its L-stereo isomeric form) compound can be administered at a concentration of 0.001 to 0.02M without any material toxicity. The copper can also be administered, via its delivery agent, to a concentration of up to 0.02M without any material toxicity.
The components (a) and (b) may be administered to a patient as a mixture or independently. If components (a) and (b) are administered independently, they may be administered substantially simultaneously or one component may be administered before the other. The timing of the administration of ,a) and (b) should be such that components (a) and (b) simultaneously achieve affective levels in body tissues for forming an effective amount of a complex of (a) and the copper of (b) in cancer cells which are susceptible to treatment therewith.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention, wherein:
FIG. 1 shows the inhibition of growth of L1210 cells in culture by S-(methylthio)-DL-homocysteine (SMETH) and its potentiation by copper ion;
FIG. 2 illustrates the potentiation of the inhibitory activity of a threshold and ID 50 concentration of S-(methylthio) -DL-homocysteine by copper ion;
FIG. 3 shows that the lower homolog of SMETH protects L1210 cells in primary culture from copper induced toxicity;
FIG. 4 shows that the cytotoxicity of S-(methylthio)-homocysteine is stereospecific;
FIG. 5 illustrates that cytidine protects L1210 cells from the cytotoxicity of S-(methylthio)-L-homocysteine and copper ion;
FIGS. 6A and 6B present the analysis of the nucleoside triphosphate content of cells incubated without (FIG. 6A) and with S-(methylthio)-L-homocysteine and copper ion (FIG. 6B);
FIG. 7 shows the progression of volume increase and lysis of L1210 cells from inhibited cultures;
FIG. 8 illustrates the flow cytometric analysis of L1210 cells from cultures inhibited with S-(methylthio)-L-homocysteine and copper ion; and
FIGS. 9A and 9B present a diagrammatic representation of glutamine, and copper - SMETH at the enzyme reactive site, in which:
FIG. 9A denotes glutamine
FIG. 9B denotes copper - SMETH.
DETAILED DESCRIPTION OF THE INVENTION
S-(methylthio)-homocysteine, (SMETH), was prepared to investigate its role as a pro-drug for delivery of homocysteine to cells. It was modeled after the lower homolog, S-(methylthio) -cysteine, (See Rabinovitz, M., and Johnson, J. M. "Synthesis of 4-thiamethionine and Its Effect on Energy Metabolism and Amino Acid Incorporation into Protein of Ehrlich Ascites Tumor Cells," Biochem. Pharmacol. 7: 100-108 (1961)), which upon intracellular reduction of the disulfide bond delivered cysteine to cells. (See Mohindru, A., Fisher, J. M., and Rabinovitz, M. `Oxidative Damage` To A Lymphoma In Primary Culture Under Aerobic Conditions Is Due Solely To A Nutritional Deficiency Of Cysteine", Proc. Am. Assoc. Cancer Res., 24:1 (1983); and Pierson, H. F., Fisher, J. M., and Rabinovitz, M., "Depletion of Extracellular Cysteine With Hydroxocobalamine And Ascorbate In Experimental Murine Cancer Chemotherapy," Cancer Res. 45:4727-4731 (1981)). Similar delivery of homocysteine would promote the formation of S-adenosylhomocysteine, a potent inhibitor of cellular methylations (See Ueland, P. M., "Pharmacological and Biochemical Aspects of S-adenosylhomocysteine and S-adenosylhomocysteine Hydrolase," Pharmacol. Rev. 34:223-253 (1982)) and projected end product for chemotherapy (See Borchart, R. T. "S-Adenosyl-L-methionine-dependent Macromolecule Methyl-transferases: Potential Targets For The Design of Chemotherapeutic Agents," J. Med. Chem. 23:347-357 (1981)). Although SMETH was found to be a potent inhibitor of cellular proliferation, it did not function by t e above anticipated mechanism.
PREPARATION OF SMETH
S-(Methylthio)-DL-homocysteine (DL-SMETH) was prepared from DL-homocysteine (Research Organics, Inc., Cleveland, OH) and methyl methanethiolsulfonate (Fairfield Chem. Co., Blythewood, S.C.) by a modification for the methylthiolation of L-cysteine as described by Smith et al. (Smith, D. J., Maggio, E. I., and Kenyon, G. L. "Simple Alkanethiol Groups For Temporary Blocking Of Sulfydryl Groups Of Enzymes," Biochemistry 14:766-771 (1975)). The L -enantiomorph, L-SMETH, was prepared following reduction of L -homocysteine (Sigma Chem. Co., St. Louis, MO) with sodium in liquid ammonia. The excess sodium was removed by the addition of ammonium chloride and the ammonia evaporated at room temperature under nitrogen. The residue was dissolved in oxygen free water and the solution neutralized to pH 6.5-7.0 with hydrochloric acid. A 1.25 molar excess of methyl methanethiolsulfonate in ethanol was added slowly and the product crystallized after 2 hours in an ice bath. The crystals were washed with ethanol and peroxide-free ether and dried over phosphorus pentoxide. An analysis was conducted (performed by Atlantic Microlab. Inc., Atlanta, GA) for SMETH, calculated, C, 33.13; H, 6.12; N,7.73; S, 35.37; Similarly found, for DL-SMETH, C, 33.21; H, 6.12; N, 7.71; S, 35.28; for L-SMETH C, 33.19; H, 6.12; N, 7.68; S, 35.3(. The racemate was resolved into two peaks and the chiral purity of L-SMETH was determined to be at least 99.9 per cent by column chromatography with a resolving column.
GROWTH AND ITS INHIBITION IN CELL CULTURE
An L1210 established murine leukemia line was maintained in RPMI 1630 medium (Quality Biologicals, Gaithersburg, MD) containing 16.5% fetal bovine serum (Advanced Biotechnologies, Silver Spring, Md.) and Gentamycin (Schering Corp., Kenilworth, NJ) 40 μg/ml. Cytotoxicity of SMETH was assessed as follows. Cells were harvested at mid-log phase (8-10×10 5 cells/ml) washed with fresh growth medium and resuspended at 1×10 5 cells per ml as determined by a model ZBI Coulter Counter (Coulter Electronics, Hialeah, Fla.). Suspensions (7 ml) were added to 25 cm 2 Corning flasks, and SMETH, 20 mM in water, with or without copper sulfate, 2 mM in water were added as dilutions in water at no greater than 10 μl/ml of the cell suspension.
Cells were grown at 37° C. for designated times in tightly stoppered flasks and cell density was determined as indicated above. Cell volume distribution was monitored with a C1000 Channelyzer with standard size latex particles (Coulter) as reference. The results are expressed as growth fraction (N--No/No) or as percent growth fraction compared to appropriate controls.
ANALYSIS OF NUCLEOSIDE TRIPHOSPHATE POOLS
For analytical studies the total incubation volume was increased to 100 ml in 175 cm 2 flasks, with the same proportions of cells and solutions described for the smaller incubation volumes. At the appropriate time, growth was terminated by shaking the flasks in ice and all further steps were performed with ice-cold reagents and under refrigerated conditions. On reaching 4° C., the cells were pelleted in a refrigerated centrifuge and extracted with 500 μl of 10% TCA. The precipitate was sedimented in a microcentrifuge tube, the supernatant fluid transferred to another such tube and extracted vigorously with an equal volume of freon (1,1,2-trichloro-1,2,2.-trifluoroethane) containing tri-n-octylamine in 4:1 proportions by volume as described by Khym (See Khym, J. X. "An Analytical System For Rapid Separation Of Tissue Nucleotides At Low Pressures On Conventional Anion Exchangers", Clin. Chem. 21:1245 -1252 (1975)). The supernatant fluid was removed and 200 μl analyzed by HPLC with the use of a Whatman 5SAX column (12.5×0.4 cm) and ammonium phosphate, pH 3.5, gradient 0.02 m to 0.7 m) over 40 minutes. The detection of components was made by UV absorbance at 254 nm.
FLOW CYTOMETRIC ANALYSIS
Following an incubation, cells were fixed and stained as described by Crissman et al. (See Crissman, H. A., Van Egmond, J., Holdrinet, R. S., Pennings, A. and Haanen, C.,"Simplified Method For DNA And Protein Staining Of Human Hematopoietic Cell Samples", Cytometry 2:59-62 (1981)). Samples were analyzed on a Becton -Dickinson FACS 440 flow cytometer (Mountain View, CA). The argon -ion laser (Coherent Innova 90-5, Palo Alto, CA) was tuned to 488 nm and operated at a power output of 200 mw in the light stabilized mode. Fluorescein isothiocyanate fluorescence was determined with the use of a 535/15 band pass filter and propidium iodide fluorascence with a 630/22 band pass filter. Data from 2×10 4 cells were collected from each sample and anulyzed in a Becto -Dickinson Consort 40 computer system.
RESULTS AND DISCUSSION
SMETH Toxicity And Copper Potentiation
SMETH was cytotoxic to L1210 cells in culture when present at a broad range of micromolar concentrations The range of inhibitory concentration was both reduced and narrowed in the presence of copper ion (FIG. 1), when the cells were also incubated for 40 hours. This ion was very effective at micromolar concentrations in bringing a threshold level of SMETH (25 μM) to a completely inhibitory concentration (FIG. 2), while being non -toxic itself at much higher levels. (The cells also were incubated for 40 hours). (See FIG. 3 of Mohindru, A., Fisher, J. M., and Rabinovitz, M. "2,9-Dimethyl-1,10-phenanthroline (neocuproine): A Potent, Copper-dependent Cytotoxin With Anti-tumor Activity.)" A concentration of 10 μM was more than adequate as a potentiating dose, but at this concentration other metal ions (Zn ++ , Mn ++ , CO ++ , Ni ++ , Cr +++ ) were ineffective. Of interest is the fact that the lower homolog of SMETH, S-(methylthio)-L-cysteine or 4-thiamethionine is not cytotoxic in the presence of copper, and actually protected L1210 cells in primary culture from growth inhibition by copper (FIG. 3) due to depletion of cysteine (See Mohindru, A., Fisher, J. M., and Rabinovitz, M., "Endogenous Copper Is Cytotoxic To A Lymphoma In Primary Culture Which Requires Thiols For Growth", Experientia 41:1064-1066 (1985) . To obtain the data for FIG. 3, the incubation was performed as in FIG. 2, except that the L1210 cells were obtained directly -rom the mouse (See Mohindru, A., Fisher, J. M., and Rabinovitz, M., "Endogenous Copper Is Cytotoxic To A Lymphoma In Primary Culture Which Requires Thiols For Growth", Experientia 41:1064-1066 (1985)). Such cells fail to grow unless supplemented with an appropriate mercaptan or disulfide (See curve ∘--∘ in FIG. 3). Hydroxyethyl Disulfide (HEDS), the oxidized form of mercaptoethanol, promoted growth, but this was inhibited by high copper concentrations (See curve -- in FIG. 3). S-(methylthio)-L-cysteine, also termed 4-thiamethionine (4TM), at a concentration of 50 μM, supported growth which was independent of copper ion concentration (See curve -- in FIG. 3). Thus, both the organic and inorganic moieties of this invention show high specificity in this inhibition.
STEREOSPECIFICITY
The racemic form of SMETH was half as active as D-SMETH (FIG. 4). D-SMETH was completely inactive at 50 μM with 50 μM copper ion. The incubation was performed with copper ion at 50 μM as described in FIG. 1 with S-(methylthio)-DL-homocysteine DL-SMETH, (See curve ∘--∘ in FIG. 4) and with the pure L-enantiomorph, L-SMETH, (See curve -- in FIG. 4). The use of 10 μM copper sulfate produced nearly identical results.
SMETH Toxicity Is Not Due To Homocysteine Delivery
Although SMETH was originally synthesized as a prodrug to deliver homocysteine to cells, inhibition analysis indicated that cytotoxicity was not due to this mechanism. Such toxicity has been reported for homocysteine thiolactone, which in combination with added adenosine and an adenosine deaminase inhibitor, such as deoxycoformycin, can block growth due to adenosylhomocysteine formation (See Kredich, N. M., and Hershfield, M. S., "S -Adenosylhomo-cysteine Toxicity In Normal An Adenosine Kinase -deficient Lymphoblasts Of Human Origin", Proc. Natl. Acad. Sci. U.S.A. 76:2450-2454 (1979)). Adenosylhomocysteine is a potent inhibitor of cellular methylation processes and, as an endogenous product of methionine metabolism trapped intracellularly by added adenosine, is the reported basis for adenosine toxicity (See Kredich, N. M., and Martin Jr., D. W., "Role of S-adenosylhomocysteine in Adenosine-mediated Toxicity In Cultured Mouse T Lymphoma Cells", Cell 12:931-938 (1977)). The present inventors have evaluated this toxicity of adenosine across a concentration range for 5 to 40 μM. At 10 μM it was not toxic to L1210 cells, but it was toxic when added together with a non-toxic concentration of L-homocysteine thiolactone. Adenosine, however, did not increase the potency of a toxic dose of SMETH as shown in Table I. The failure of adenosine to promote SMETH toxicity suggested that such toxicity was not due to adenosylhomocysteine formation.
TABLE I______________________________________Adenosine Does Not Potentiate SMETH Cytotoxicity percent inhibition______________________________________L-Homocysteine Thiolactone 200 μM 5plus Adenosine 10 μMDeoxycoformycin 20 μM 39DL-SMETH 75 μm 46Plus Adenosine 10 μmDeoxycoformycin 20 μm 46______________________________________ Percent inhibition is determined from the percent of growth fraction obtained with and without the compounds indicated.
Glutamine Protection Against SMETH Toxicity
Glutamine, at millimolar concentrations which supported growth, protected cells against SMETH and SMETH plug Cu ++ as shown in Table II.
TABLE II______________________________________Glutamine Protects L1210 Cells fromGrowth Inhibition by SMETH andCopper-SMETH in a competitive manner. L-SMETH L-SMETH 10 μMGlutamine Conc. 50 μM Cu.sup.++, 10 μMmM growth (percent of control)______________________________________0.5 15 01.0 31 7.72.0 58 584.0 98 100______________________________________
At these concentrations the full range for almost complete inhibition to complete protection is evident. This type of protection was not seen with other amino acids, some having a closer structural resemblance to SMETH. In fact, as can be seen in Table III, such amino acids promoted SMETH toxicity.
TABLE III______________________________________Potentiation of Growth Inhibition by SMETH with Amino Acids Conc.* for 50% further inhibition mM______________________________________L-Leucine 1S-Ethyl-L-cysteine 1DL-Isopropionine 2L-Methionine 2L-Norleucine 2.5______________________________________ *Estimated by interpolation. The DLSMETH concentration was 75 or 100 μM.
This promotion of inhibitory activity may be due to the phenomenon termed "trans-stimulation of uptake" which is common in the amino acid series (See Schafer, J. A., and Jacquez, J. A., "Transport Of Amino Acids In Ehrlich Ascites Cells: Competitive Stimulation", Biochim. Biophys. Acta 135:741-750 (1967)). Such increased uptake would increase cytotoxity. Further analysis of this problem would require radioactive material.
Amination Of Uridine To Cytidine As Site Of Inhibition
Among the several biochemical roles of glutamine, that involving the amination of uridine-5'-triphosphate (UTP) to cytidine-5'-triphosphate (CTP) was the only locus blocked by copper-SMETH. This conclusion was sustained by the following two observations: (1) Cytidine alone protected the cells from growth inhibition, and this protection was non-competitive, equivalent concentrations of cytidine being equally effective at two concentrations of copper-SMETH which gave maximal growth inhibition (See FIG. 5). (To obtain the data in FIG. 5, the cells were incubated with S-(methylthio)-L-homocysteine 15 μM, (curve ∘--∘) and 30 μM (curve -- )together with their corresponding concentrations of copper sulfate). Uridine and guanosine were ineffective in such protection; and (2) HPLC analysis of cells inhibited in growth showed greater than a 1/3 diminution of CTP content but a two-fold elevation of UTP, ATP and GTP (See FIG. 6). To obtain the data in FIG. 6, the cells were incubated for 14 hours in the medium described in the above section entitled Growth And Its Inhibition In Cell Culture, but containing only 1 mM glutamine, 1/2 the normal concentration. 1he inhibited culture also contained 15 μM each of S-(methylthio)-L-homocysteine and copper sulfate. At the end of the incubation, the cell density in the inhibited culture was determined, and &he entire population centrifuged for analysis. An aliquot containing an equal number of cells from the control culture was removed for comparison, and both samples processed and analyzed as described in the above section entitled Analysis of Nucleoside Triphosphate Pools. In FIG. 6A represents controls, and FIG. 6B represents inhibited culture. Letters with their corresponding peaks indicate the separated nucleotide triphosphate shown below, followed by retention times and the effect of copper-SMETH.
C, cytidine triphosphate; 20.0 min, decreased to 29% of control
U, uridine triphosphate; 21.3 min, increased to 233% of control
A, adenosine triphosphate; 22.6 min, increased to 196% of control
G, guanosine triphosphate; 27.5 min, increased to 186% of control
The modal volume of the control cells was (20 cubic microns and that of the inhibited cells 1140 cubic microns. Other uncharacterized peaks were also elevated in the inhibited sample. Such elevated levels of cellular constituents may be due to the increased volume of inhibited cells as described below.
Cell Expansion And Unbalanced Growth
Characteristic of SMETH and copper-SMETH growth inhibition is the progressive increase in cell volume observed over a two day period (See FIG. 7). To obtain the data in FIG. 7, cells were incubated under standard conditions with S-(methylthio)-L -homocysteine and copper sulfate, each 15 μM, and cell volume monitored during the course of the incubation. Curve (1) denotes control cells, modal volume in cubic microns: 870; Curve (2) denotes cells with inhibitor for 16 hours, modal volume in cubic microns: 915; Curve (3) denotes cells with inhibitor for 24 hours, modal volume in cubic microns: 1270; and Curve (4) denotes cells with inhibitor for 40 hours, modal volume in cubic microns: 1820. Ultimately, the cells burst, as indicated by the accumulation of debris shown near the ordinate. Flow cytometric analysis of control and inhibited, swollen cells showed increases in fluorescein isothiocyanate staining and propidium iodide staining in the latter, which are indicative of increases in protein and DNA per cell, respectively. (See FIG. 8). To obtain the data in FIG. 8, the cells were incubated for 24 hours without and with S -(methylthio)-L-homocysteine and copper sulfate as described in regard to FIG. 6. At the end of the incubation, cell number and cell volume distribution (lower panel) were determined and an equal number of cells were removed for staining and analysis as described in the above section entitled Flow Cytometric Analysis. Over 1×10 4 cells were analyzed and inhibited cells showed a 60% increase in protein, a 35% increase in DNA and a 100% increase in volume. The following legend applies to FIG. 8:
FWD SCR =forward scatter;
90° SCR =90° scatter of light;
The Abscissa denotes the magnitude of item shown in panel;
The Ordinate denotes the relative number of cells.
The correspondence between protein distribution and 90° scatter with volume distribution of the cells is particularly striking.
Homocysteine And Metal Binding
Cecil and McPhee (See Cecil, R., and McPhee, J. R., "Further Studies On The Reaction Of Disulfides With Silver Nitrate", Biochem. J. 66:538-543 (1957)) observed that homocystine reacted with silver ion at a rate 267 times that of cystine and that this increased rate was dependent upon the presence of unsubstituted amino groups. They indicated (See Cecil, P., and McPhee, J. R., "The Sulfur Chemistry Of Proteins", Adv. Protein Chem. 14:299-302 (1959)) that the metal ion was bound by ammine formation and therefore brought closer to the disulfide bond. Appropriate configuration required that two methylene groups were spaced between the unsubstituted amino group and the disulfide, possibly to allow hydrogen bond formation in the unsubstituted amino acid. Thus, a similar reaction rate did not occur with cystine. It is noteworthy that SMETH has the same amino to disulfide configuration as homocystine, and that the cuprous ion has nearly identical reactivities as the silver ion (See Cotton, F. A., and Wilkinson, G., Advanced Inorganic Chemistry. 4th Edition, John Wiley & Sons, NY, p. 966, (1980)).
Copper - Disulfide Bonding And Reactivity
The coordination between the cuprous ion and a symmetrical disulfide as described by Ottersen, Warner and Seff (Ottersen, T., Warner, L. G., and Seff, K., "Synthesis And Crystal Structure Of A Dimeric Cyclic Copper (I)-aliphatic Disulfide Complex: cyclo-Di-μ-{bis[2-(N,N-dimethylamino)ethyl]disulfide}-dicopper(I) tetrafluoro-borate," Inorg. Chem. 13:1904-911 (1974)) involves a lengthening of the disulfide bond and thus its weakening: ##STR1## The ##STR2## moiety thus becomes a much better leaving group than the original --SR.
The sulfur-sulfur bond becomes more susceptible to nucleophilic attack, and the structure may be considered an example of an intermediate in concomitant electrophilic and nucleophilic catalysis of the scission of this bond as described by Kice (See Kice, J. L., "Electrophilic And Nucleophilic Catalysis Of The Scission Of The Sulfur-Sulfur Bond", Accts. Chem. Res. 1:58-64 (1968); Kice, J. L., The Sulfur-sulfur Bond, in Sulfur in Organic and Inorganic Chemistry Vol. 1, (A. Senning, ed.). Marcel Dekker, NY, 195,196 (1971)): ##STR3##
Relation To Reaction With The Enzyme Active Site
The positioning of glutamine in CTP synthetase relative to its reactive thiolate anion can be represented diagramatically as indicated by Levitzki (See Levitzki, A., "The allosteric control of CTF Synthetase", in The Enzymes of Glutamine Metabolism (See S. Prusiner, and E. R. Stadtman, eds.); Academic Press, NY 505-521 (1973)) in FIG. 9A. In this representation, the glutamine subsequently loses its amide group and reacts to form a thio-ester. A corresponding positioning of copper-SMETH is shown in the FIG. 9B. This positioning is dependent upon the "natural" L configuration of SMETH and places the nucleophilic thiolate ion in close proximity to the sulfonium moiety of the copper disulfide function. In accordance with the reactions described above, the cuprous sulfide of homocysteine would act as the leaving group and the enzyme would be methylthiolated. The possibility that migration of the copper to the sulfur of the methylthio-moiety of SMETH would make the methylthio-moiety the leaving group cannot be ignored.
Comparison With Other Glutamine Amidotransferase Inhibitors
The activity of copper-SMETH differs from that of the natural amido-transferase inhibitors, azaserine, diazo-oxo-norleucine and acivicin in that only one critical cellular pathway is blocked, the amination of UPT to CTP. The other inhibitors also block some sites in purine biosynthesis (See Livingston, R. B., Venditti, J. M., Cooney, D. A., and Carter, S. K., "Glutamine Antagonists In Chemotherapy", Adv. Pharmacol. Chemotherap. 8:57-120 (1970)) including the amination step for the synthesis of guanosine monophosphate (See Neil, G. L., Berger, A. E., Bhuyan, B. K., Blowers, C. L., and Kuentzel, S. L., "Studies Of The Biochemical Pharmacology Of The Fermentation-derived Antitumor Agent, (alphaS,5S)-alpha -amino-3-chloro-4,5-dihydro-5-isoxazoleacetizacid (AT-125)", Adv. Enzyme Regul. 17:375-398 (1978); and Neil, G. L., Berger, A. E., McPartland, R. P., Grindey, G. B., and Bloch, A. Biochemical And Pharmacological Effects Of The Fermentation-derived antitumor Agent, (αS,5S-α-amino-3-chloro-4,5-dihydro-5-isoxazoleacetic acid (AT-125). Cancer Res. 39:852-865 (1979)). There is currently no explanation for this difference. It should be noted, however, that the reactive center of copper-SMETH is internal (FIG. 9), while in the other glutamine analogs the reactive site may be considered terminal. This introduces the concept of bulk tolerance in inhibitor specificity, for the methylthio- and copper moieties must be acceptable within the reactive site of the enzyme. This factor could be evaluated by determining the potency of copper-SMETH as an inhibitor for the other glutamine amidotransferase. Also, groups larger than methyl can be introduced in the mixed disulfide, to yet further challenge the bulk tolerance of the enzymes from different tissues.
Possible Relationship Between The Biochemical And Cellular Lesions
Homocysteine has been shown to promote endothelial cell damage via copper catalyzed hydrogen peroxide generation (See Starkebaum, G. and Harlan, J. M., "Endothelial Cell Injury Due To Copper -catalyzed Hydrogen Peroxide Generation From Homocysteine", J. Clin. Invest. 77:1370-1376 (1986)), to be toxic by blocking methionine metabolism via its adenosyl derivative (See Djurhuus, R., Svardal, A. M., Ueland, P. M., Male, R. and Lillehaug, J. R., "Growth Support And Toxicity Of Homocysteine And Its Effects On Methionine Metabolism In Non-transformed and Chemically Transformed C3H/10T1/2 Cells", Carcinogenesis 9:9-16, (1988)) and homocysteine thiolactone may be toxic due to acylations of cellular constituents by the reactive thiolactone moiety (See Dudman, N. P. B. and Wilcken, D. E. L., "Homocysteine Thiolactone And Experimental Homocysteinemia", Biochem. Med. 27:244-253 (1982)). Since cells can be protected from SMETH and copper-SMETH inhibitions by glutamine and cytidine, these possible alternative mechanisms of cytotoxicity may be considered inoperative in the present system.
The marked swelling and lysis from the S1ETH and copper-SMETH promoted CTP deficiency may be a consequence <f a block in phospholipid biosynthesis for plasma membrane generation (See Vance, D. E. in Biochemistry of Lipids and Membranes (D. E. Vance and J. E. Vance, eds. pp. 242-270 (1985)). This appears probable because the inventors report that DNA and protein synthesis had continued in the inhibited swollen cells and the observation (Ibid.) that the Km of the reactions involving CTP in phospholipid biosynthesis is higher than those of nucleic acid formation. Thus, as the availability of CTP becomes limiting, a block in phospholipid biosynthesis would be the first to become evident, and could result in unbalanced growth, membrane pathology, swelling and lysis.
The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims:
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An injectable pharmaceutical composition for the treatment of cancers susceptible to treatment therewith, the composition comprising:
(a) an effective amount of S-(methylthio)-DL-homocysteine or the L-enantimorph thereof;
(b) an effective amount of a copper chelate of nitrilotriacetic acid or an effective amount of a copper chelate of a bis-thiosemicarbazone; and
(c) a pharmaceutically acceptable carrier.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 61/142,534, entitled “An Integrated Processing Workflow for Processing Time Series Data Embedded in High Noise: Application to HFM Data,” filed Jan. 5, 2009.
BACKGROUND OF THE INVENTION
[0002] The present invention is generally related to seismic data processing, and more particularly to seismic data processing of data from a plurality of sensors for purposes such as monitoring hydraulic fracturing treatments. Seismic data processing has long been associated with the exploration and development of subterranean resources such as hydrocarbon reservoirs. While numerous technological advances have been made in the art, at least some potentially useful seismic data is not fully utilized because of unfavorable signal to noise ratios.
[0003] One example of a procedure that could be enhanced by improved seismic data processing is Hydraulic fracture monitoring (HFM). Hydraulic fracturing is a stimulation treatment via which reservoir permeability is improved by subjecting a formation adjacent to a portion of a borehole to increased pressure in order to create and widen fractures in the formation, thereby improving oil and gas recovery. HFM techniques are utilized to evaluate the propagation paths and thickness of the fractures. Some HFM techniques that are known in the art are described in: R. D. Barree, “Application of pre-frac injection/falloff tests in fissured reservoirs field examples,” SPE paper 39932, presented at the 1998 SPE Rocky Mountain Regional Conference, Denver, Apr. 5-8, 1998; C. L. Cipolla and C. A. Wright, “State-of-the-art in hydraulic fracture diagnostics,” SPE paper 64434, presented at the SPE Asia Pacific Oil and Gas Conference and Exhibition held in Brisbane, Australia, October 1618, 2000; C. A. Wright et. al, “Downhole tiltmeter fracture mapping: A new tool for directly measuring hydraulic fracture dimensions,” SPE paper 49193, Presented at 1998 SPE Annual Technical Conference, New Orleans, 1998; C. A. Wright et. al, “Surface tiltmeter fracture mapping reaches new depths 10,000 feet, and beyond,” SPE paper 39919, presented at the 1998 SPE Rocky Mountain Regional Conference, Denver, Apr. 5-8, 1998; N. R. Warpinski et. al, “Mapping hydraulic fracture growth and geometry using microseismic events detected by a wireline retrievable accelerometer array,” SPE 40014 presented at the 1998 SPE Gas Technology Symposium in Calgary, Canada, Mar. 15-16, 1998; R. L. Johnson Jr. and R. A. Woodroof Jr., “The application of hydraulic fracturing models in conjunction with tracer surveys to characterize and optimize fracture treatments in the brushy canyon formation, southeastern new mexico,” SPE paper 36470, presented at the 1996 Annual Technical Conference and Exhibition, Denver, Oct. 6-9, 1996; J. T. Rutledge and W. S. Phillips, “Hydraulic stimulation of natural fractures as revealed by induced microearthquakes, carthage cotton valley gas field, east texas,” Geophysics, 68:441-452, 2003; and N. R. Warpinski, S. L. Wolhart, and C. A. Wright, “Analysis and prediction of microseismicity induced by hydraulic fracturing,” SPE Journal, pages 24-33, March 2004. The last two references listed above describe “microseismic” techniques. Microseismic events occur during hydraulic fracture treatment when pre-existing planes of weakness in the reservoir and surrounding layers undergo shear slippage due to changes in stress and pore pressure. The resulting microseismic waves can be recorded by arrays of multicomponent geophones placed in the well undergoing treatment or a nearby monitoring well. However, the recorded microseismic waveforms are usually complex wavetrains containing high amplitude noise as well as borehole waves excited by operation of pumps located at the surface. Consequently, accurately estimating the time of arrival of various recorded events such as p- and s-wave arrivals is technologically challenging.
SUMMARY OF THE INVENTION
[0004] A method in accordance with the invention comprises the steps of: using a plurality of sensors to acquire time series data corrupted by noise and including signals caused by microseismic events in a subterranean formation; processing discrete portions of the data to determine, for each portion, whether an event of interest is present; for each portion containing an event of interest, determining a first arrival time of the event and delay across the plurality of sensors; and using the first arrival time and delay to spatially map fractures in a subterranean formation.
[0005] A computer program product in accordance with the invention comprises a computer usable medium having a computer readable program code embodied therein, said computer readable program code adapted to be executed to implement a method for event classification, said method comprising: using a plurality of sensors to acquire time series data corrupted by noise and including signals caused by microseismic events in a subterranean formation; processing discrete portions of the data to determine, for each portion, whether an event of interest is present; for each portion containing an event of interest, determining a first arrival time of the event and delay across the plurality of sensors; and using the first arrival time and delay to spatially map fractures in a subterranean formation.
[0006] Apparatus in accordance with the invention comprises: an array of receivers that acquire time series data corrupted by noise and including signals caused by microseismic events in a subterranean formation; processing circuitry for processing discrete portions of the data to determine, for each portion, whether an event of interest is present; and for each portion containing an event of interest, determining a first arrival time of the event and delay across the plurality of sensors; and an interface which outputs information associated with spatially mapping fractures in a subterranean formation based on the first arrival time and delay.
BRIEF DESCRIPTION OF THE FIGURES
[0007] FIG. 1 illustrates apparatus for performing and monitoring hydraulic fracturing using microseismic data.
[0008] FIG. 2 illustrates microseismic wave generation associated with hydraulic fracturing in greater detail.
[0009] FIG. 3 is a block diagram of a method for processing time series data embedded in high noise.
[0010] FIG. 4 illustrates the event detection and confidence indicator generation step in greater detail.
DETAILED DESCRIPTION
[0011] Referring to FIG. 1 , in order to implement a hydraulic fracturing treatment of a borehole (“treatment borehole”) ( 100 ), treatment fluid ( 102 ) is pumped into the borehole from a surface reservoir using a pump ( 104 ). The treatment fluid may be hydraulically confined to a particular portion of the borehole by using packers. For example, if the borehole includes a completion then some or all perforations ( 106 ) in a particular area may be hydraulically isolated from other portions of the borehole so that the fracturing treatment is performed on a particular portion of the formation ( 108 ). In order to implement the treatment, the pressure of the treatment fluid is increased using the pump. The communication of that increased pressure to the formation tends to create new fractures and widen existing fractures (collectively, fractures ( 110 )) in the formation.
[0012] Referring to FIGS. 1 and 2 , the hydraulic fracturing treatment described above causes microseismic events ( 200 ) to occur. As a result, microseismic waves ( 202 ) are emitted when pre-existing planes of weakness in the reservoir and surrounding layers undergo shear slippage due to changes in stress and pore pressure. The emitted microseismic waves ( 202 ) are recorded by arrays of multicomponent geophones ( 112 ) placed within the treatment borehole ( 100 ), a monitoring borehole ( 114 ), or at the surface ( 115 ). The microseismic waves detected by the geophones are processed by a hydrophone digitizer, recorder and analyzer device ( 116 ) in order to monitor the hydraulic fracturing treatment. For example, the creation, migration and change in fractures may be monitored in terms of both location and volume. The information obtained by monitoring may be used to help control aspects of the fracturing treatment such as pressure changes and fluid composition, and also to determine when to cease the treatment. Further, use of the information to control the treatment may be automated.
[0013] A method for processing time series data embedded in noise is illustrated in FIG. 3 . The noise may originate from any of various sources including but not limited to pumps and background events. Some or all of these steps may be performed by the hydrophone digitizer, recorder and analyzer device ( 116 , FIG. 1 ). Those skilled in the art will appreciate that processing circuitry, computer programs stored on a computer readable medium, I/O interfaces and other resources may be used to implement the steps. Input data recorded by a borehole seismic tool or geophone array is obtained in step ( 301 ). Step ( 302 ) is to filter the recorded data to remove as much noise as practical from the recorded data to facilitate first motion detection. The result of step ( 302 ) is filtered data together with residual noise. The noise removal step can be automated or, alternatively, omitted. In other words, flow may proceed to step ( 304 ) either from step ( 302 ) or step ( 303 ) because filtering may be omitted at the instruction of the operator. When the filtering step ( 302 ) is omitted, the operator may manually estimate the noise signal and the signature of the signal of interest, i.e. the HFM event, in step ( 303 ). Alternatively, step ( 303 ) can be automated by using previous sections of the data where no strong signal was detected. Step ( 304 ) is event detection. Event detection provides statistical information indicative of the presence or absence of HFM events in the recorded data. In one embodiment a sliding window is used to scan portions of the recorded data along the time axis. For each time location of the window, a hypothesis test is performed to detect whether an HFM event is present in the window. The output of step ( 304 ) is indicative of the window locations containing candidate HFM events. The output may also include an indication of a level of confidence in the presence of an HFM event for each window location. Step ( 305 ) step is delay estimation. For each window location containing a candidate HFM event as indicated by the output of step ( 304 ) a time delay estimation algorithm is used to determine the first arrival time of the event. The determined arrival time and delays will be used later to spatially map fractures in the reservoir.
[0014] FIG. 4 illustrates the event detection and confidence indicator generating step ( 304 , FIG. 3 ) in greater detail. The two main components of the technique are estimation of the transfer function and estimation of the noise power spectrum. The step is distinct from the well known technique of detecting the presence of an event based on an energy ratio function. According to that well known technique, the ratio between the instantaneous trace energy normalized by the cumulative trace energy is computed as follows:
[0000]
Ef
(
t
)
=
∫
τ
τ
+
T
x
2
(
t
)
t
∫
0
T
x
2
(
t
)
t
(
1
)
[0000] where T is the width of the running window used to compute the instantaneous energy. The absence or presence of an event is then detected based on a threshold applied to the energy ratio function. A limitation of the ratio-based technique is that it does not function well when the signal to noise ratio (SNR) is unfavorable, i.e., when the signal amplitude is not significantly greater than the noise amplitude. Further, the ratio-based technique does not yield an indication of confidence that the detected event is a signal of interest rather than noise.
[0015] In the illustrated embodiment a statistical procedure is utilized for event localization using both the signal and noise information from the array data. The recorded data is scanned using a time-sliding window. At the various window locations a determination is made whether the location contains a signal of interest. This can be viewed as a windowed time series x ml (t), m=1, . . . , Nr; l=x, y, z; t=1, . . . , N,
[0000] where Nr, L, and N are respectively, the number of receivers in the array, the component type and the length of the window. The time series can be modeled as:
[0000] x ml ( t )= s ml ( t )+ε ml ( t ) (2)
[0016] Vectors X(t), S(t), and ε(t) are built using some or all of the components above. Letting X N =[X(1), . . . , X(N)], assume that the noise process is stationary Gaussian with power spectrum density F(λ), i.e. ε(λ)˜ (0,F(λ)), where λ is the frequency. The signal S(t) is modeled as a deterministic but unknown quantity belonging to a signal class given by a scaled and delayed version of a common trace s o (t), which, in turn, is obtained by convolving a Ricker wavelet with an FIR filter,
[0000] s 0 ( t )= s R ( t )* h ( t ) (3)
[0000] where * denotes convolution, SR (t) is the Ricker wavelet and
[0000]
h
(
t
)
=
{
h
t
,
t
∈
[
0
,
P
-
1
]
0
,
otherwise
(
4
)
[0000] is a P-order FIR filter. The signal is then given by
[0000] S ( t )=μ G ( t )* s 0 ( t ) (5)
[0000] where
[0000] {tilde over (G)} ml (λ)=exp(− iδ n2 λ)exp(− jφ e ):φ e ={0,π} (6)
[0000] is the transfer function (in the frequency domain) of the media. This model, incorporating delays and (0,π) phase shifts, yields a good empirical fit to real HFM signals.
[0017] The event detection problem can be considered as testing between the following two hypotheses:
[0000] H 0 :μ=0
[0000] H 1 :μ≠0 (7)
[0018] Assuming that F(λ) is known or has been estimated, the log likelihood function under H 0 can be calculated. For the Fourier Domain data, {tilde over (X)} j ={tilde over (X)}(λ j ) with {tilde over (X)}(λ)= T (X(t)) and λ i =2πj/N are the Fourier frequencies.
[0000] {tilde over (X)} N =[{tilde over (X)} 1 , . . . , {tilde over (X)} N f ], N f =└(N−1)/2┘. (8)
Then
[0019]
LL
(
H
0
X
_
N
)
=
K
-
∑
j
=
1
N
f
X
_
j
†
F
j
-
1
X
_
j
(
9
)
[0000] where j indexes the Fourier coefficients of the corresponding quantities. Under H 1 , the signal model in frequency domain is given by:
[0000] {tilde over (S)} (λ)=μ {tilde over (G)} (λ) {tilde over (s)} R (λ) H (λ) (10)
[0000] where
[0000]
H
(
λ
)
=
∑
p
=
0
P
-
1
h
p
exp
(
-
2πλ
p
)
=
Ω
λ
h
_
,
(
11
)
[0000] with Ω(λ)=[1, exp(−i2πλ), . . . , exp(−2πλ(P−1)] and h =[h 0 , . . . h p-1 ] T . Then
[0000] {tilde over (S)} (λ)=μ {tilde over (G)} (λ) {tilde over (s)} R (λ)Ω(λ) h (12)
[0000] where μ and h are unknown and have to be determined. Accordingly, μ is absorbed into h , the frequency domain quantities above are represented at the Fourier frequencies λ j by appending the subscript j; e.g. {tilde over (S)} j ={tilde over (S)}(λ j ) etc., and the likelihood under H 1 is as follows:
[0000]
LL
(
H
1
,
h
X
_
N
)
=
K
-
∑
j
=
1
N
f
{
(
X
_
j
-
S
_
j
)
)
†
F
j
-
1
(
X
_
j
-
S
_
j
)
=
K
-
∑
j
=
1
N
j
(
X
_
j
-
G
j
S
R
,
j
Ω
j
h
_
)
†
F
j
-
1
(
X
_
j
-
G
j
S
R
,
j
Ω
j
h
_
)
=
K
-
∑
j
=
1
N
f
{
(
X
_
j
-
H
j
h
_
)
†
F
j
-
1
(
X
_
j
-
H
j
h
_
)
(
13
)
[0000] where G j S Rj Ω j =H j . The optimum {tilde over (h)} obtained, for example, by setting
[0000]
∂
∂
h
LL
=
0
,
[0000] from which
[0000]
h
_
^
=
(
∑
j
=
1
N
f
H
j
†
F
j
-
1
H
j
)
-
1
(
∑
j
=
1
N
f
H
j
†
F
j
-
1
X
_
j
)
(
14
)
[0020] Substituting back into Eq. (13) and simplifying, the test statistic for the hypothesis testing problem is:
[0000]
τ
(
X
N
)
=
LL
H
1
-
LL
H
0
=
(
∑
j
=
1
N
f
H
j
†
F
j
-
1
X
_
j
)
†
(
∑
j
=
1
N
f
H
j
†
F
j
-
1
H
j
)
-
1
(
∑
j
=
1
N
f
H
j
†
F
j
-
1
X
_
j
)
=
Δ
†
Γ
-
1
Δ
(
15
)
[0000] where the vector Δ=Σ j=1 N f H j † F j −1 {tilde over (X)} j and the matrix Γ=Σ j=1 N f H j † F j −1 H j . Letting W j =F j −1 G j and v j =G j † F j −1 G j , it follows that:
[0000]
Γ
mn
=
∑
j
=
1
N
f
S
R
,
j
2
v
j
exp
(
2πλ
j
(
m
-
n
)
)
,
m
,
n
=
1
,
…
,
P
Δ
k
=
∑
j
=
1
N
f
S
R
,
j
*
W
j
†
X
_
j
exp
(
2πλ
j
k
)
,
k
=
1
,
…
,
P
.
(
16
)
[0021] An event will be considered present in the window if
[0000] τ( X N )>τ o . (17)
[0022] The threshold is chosen based on the statistical behavior of the τ under H o ; with Gaussian noise, it is possible to set this independently of the actual noise covariance and obtain a constant false alarm rate (CFAR) detector for testing at a given level of significance. Additionally the value of the test statistic gives a measure of the confidence level in the presence of an event in a given window, which is useful for downstream processing.
[0023] It will be appreciated that the transfer function G(λ) cf Eq. (6) is assumed to be known in the event detection algorithm described above. However, in practice that will not always be a safe assumption. Because performance of the detector is not particularly sensitive to the precise value of the delay used, it is feasible to iterate over a coarse grid of delays as well as phase shifts and choose the highest value of the test statistic function for the purpose of detection. However, this increases the computational load. An alternative approach is to consider the three components at only one receiver of interest. Because it is reasonable to consider that a signal recorded by a 3C geophone will arrive at the same time on all the components, the transfer function presented previously can still be used by setting the time delays to zeros.
[0024] It will be appreciated that noise power spectrum density F(λ) is assumed to be known for the automatic window selection described above. However, in practice that will not always be a safe assumption. The power spectrum can be estimated via the multiple-taper method described in J. M. Lees and J. Park, “Multiple-taper spectral analysis: A stand-alone c-subroutine,” Computers & Geosciences, 21:199-236, 1995; and D. J. Thomson, “Spectrum estimation and harmonic analysis,” Proceedings of the IEEE, 70:1055-1096, 1982. Multi-taper spectral analysis provides a good spectrum estimate for narrow band or single frequency analysis. It minimizes the spectral leakage by applying window weighting functions or tapers to the time series data before the Fourier transform, and uses a special set of orthonormal tapers which are combined to get an average estimate of the spectrum so as to reduce the variance of the overall spectrum estimate. This special set of tapers, called the discrete prolate spheroidal sequences (see D. Slepian, “Prolate spheroidal wave functions, fourier analysis, and uncertainty—v: The discrete case,” Bell System Technical Journal, 57:1371-430, 1978) are useful for managing the trade-off of bias (leakage) versus variance.
[0025] The multitaper spectral analysis includes three steps. First, a set of K Slepian prolate sequences are computed by solving an eigenvector problem for a Toeplitz system (see Id.). These K Slepian tapers, w(1), . . . , w(K), are then applied to the data x, and the fast Fourier Transform (FFT) is applied to each tapered copy of the data resulting in K eigenspectra:
[0000]
Y
k
(
λ
j
)
=
1
N
∑
n
=
1
N
ω
n
(
k
)
x
n
exp
(
λ
j
n
)
,
k
=
1
,
…
K
.
(
18
)
[0026] Finally, the eigenspectra are combined to get the final spectrum estimation, e.g., using:
[0000]
F
(
λ
j
)
=
∑
k
=
1
K
1
α
k
Y
k
(
λ
j
)
2
(
19
)
[0000] where α k is the bandwidth retention factor which specifies the proportion of narrow-band spectral energy captured by the kth Slepian taper for a white-noise process. Note that α k ≈1 for tapers that possess good resistance to spectral leakage. Adaptive methods to further optimize the leakage could also be used, but the above approach is adequate in practice. The noise power spectrum is assumed to vary slowly and therefore does not have to be computed on every window. Rather, segments of signal free data, obtained for example from windows on which the detector has already been applied and yielded no event, can be used to compute this estimate and applied to a number of windows in the vicinity. Alternatively the noise output of a denoising step can be used for this computation.
[0027] Referring again to FIG. 3 , the delay estimation step ( 305 ) will be described in greater detail. Assuming the sliding observation window described above for event localization contains the signals of interest, the next step is to estimate the relative time delays across an array of receivers. In the illustrated embodiment the data is collected with multi-component geophones, thereby allowing data analysis to be based on independent components or all components simultaneously. Two signals x 1 (t) and x 2 (t) recorded at two receiver positions can be mathematically represented by the following equation:
[0000] x 1 ( t )= s ( t )* f ( t )+ n 1 ( t )
[0000] x 2 ( t )= s ( t−τ 0 )* h ( t )+ n 2 ( t ) (20)
[0000] where, s(t) is the signal sent into the formation, f(t) and g(t) correspond to the impulse response of the medium, and n 2 (t) and n 1 (t) correspond to the noise recorded by each receiver. Usually the noise is not considered to be correlated with the input signal sent to the medium. However, the noise recorded by two receivers can be correlated. In the case of sonic and seismic data, the problem can be simplified by assuming that the medium properties are the same and the noise data have the same statistical properties across the array. Under the previous assumptions, the general equations can be simplified to
[0000] x 1 ( t )= s ( t )* g ( t )+ n 1 ( t )
[0000] x 2 ( t )= s ( t−τ 0 )* g ( t )+ n 2 ( t ) (21)
[0028] One of the most commonly used methods for estimating delay between two or more receivers is cross-correlation, i.e.:
[0000] τ I 1 I 2 (τ)= E[x 1 ( t ) x 2 ( t +τ)]= [ P I 1 I 2 ( w )] (22)
[0000] where E is the expectation function, F −1 is the inverse Fourier transform and P x1x2 (w) is the cross-spectrum, defined as:
[0000] P I 1 I 2 ( w )= E[X 1 *( w ) X 2 ( w )] (23)
[0029] The argument maximizing the cross-correlation r x1x2 (τ) is taken as the estimate of the time delay τ 0 between signals x 1 (t) and x 2 (t). With the signal model described in Equation (20), the cross spectrum can be partitioned into three components
[0000]
P
x
1
x
2
(
ω
)
=
E
[
X
1
*
(
ω
)
X
2
(
ω
)
]
=
F
*
(
ω
)
H
(
ω
)
media
Pss
(
ω
)
source
-
jωτ
0
delay
+
P
n
1
n
2
(
ω
)
noise
(
24
)
[0030] Note that this delay estimation is colored by the propagation media, the source signature and the correlated noises. To suppress the effects of the transmission media and the source signal, the cross-spectrum is normalized by the individual autospectra, resulting in the complex coherence function:
[0000]
γ
x
1
x
2
(
ω
)
=
P
x
1
x
2
(
ω
)
P
x
1
x
1
(
ω
)
P
x
2
x
2
(
ω
)
=
H
(
ω
)
/
F
(
ω
)
H
(
ω
)
/
F
(
ω
)
media
U
(
ω
)
SNR
-
jωτ
0
delay
+
P
n
1
n
2
(
ω
)
P
x
1
x
1
(
ω
)
P
x
2
x
2
(
ω
)
noise
(
25
)
[0031] where U(w) is a combined measure of signal-to-noise ratios U x1 (w) and U x2 (w),
[0000]
U
(
ω
)
=
1
(
1
+
1
U
x
1
(
ω
)
)
(
1
+
1
U
x
2
(
ω
)
)
(
26
)
[0032] The coherence-correlation function is obtained by taking the inverse Fourier transform of γ x1x2 (w).
[0033] Detection techniques based on coherence provide advantages regarding the cross-correlation. The amplitudes of the propagation are normalized, and the coherence function depends on the signal-to-noise ratio rather than on the signal spectrum itself. In the limit when the noise is negligible, U(w) will become unity that does not depend on the spectral content of the source. Nevertheless, the noise correlation term still exists in the coherence function, although normalized. One of the limitations of the second-order technique is that it is not able to properly manage the correlated noise across the array.
[0034] In an alternative embodiment the detection step is based on third order statistics, namely bispectral-correlation. The bispectrum between two signals x 1 (t) and x 2 (t) is defined as
[0000] B I 1 I 2 I 1 ( w 1 ,w 2 )= E[X 2 ( w 1) X 1 ( w 2) X 1 *( w 1 +w 2)] (27)
[0035] The bispectrum ratio is defined as
[0000]
β
x
1
x
2
x
1
(
ω
1
,
ω
2
)
=
B
x
1
x
2
x
1
(
ω
1
,
ω
2
)
B
x
1
x
1
x
1
(
ω
1
,
ω
2
)
=
H
(
ω
1
)
/
F
(
ω
1
)
media
-
jω
1
τ
0
delay
(
28
)
[0000] which eliminates the correlation of the Gaussian noise, although the ratio still keeps the medium transfer function. The bispectral-correlation is obtained by summing up β x1x2x1 (w 1 , w 2 ) along w 2 and then taking the 1-D inverse Fourier transform:
[0000]
ρ
x
1
x
2
(
τ
)
=
F
-
1
[
∑
ω
2
β
x
1
x
2
x
1
(
ω
1
,
ω
2
)
]
(
29
)
[0036] One extension of the previous method is bicoherence-correlation based on the bicoherence, which is the normalized bispectrum:
[0000]
b
x
1
x
2
x
1
(
ω
1
,
ω
2
)
=
B
x
1
x
2
x
1
(
ω
1
,
ω
2
)
P
x
1
x
1
(
ω
1
)
P
x
2
x
2
(
ω
2
)
P
x
1
x
1
(
ω
1
+
ω
2
)
=
H
(
ω
1
)
/
F
(
ω
1
)
H
(
ω
1
)
/
F
(
ω
1
)
media
U
_
(
ω
1
)
SNR
-
jω
1
τ
0
delay
(
30
)
[0000] where Ũ(w 1 ) can be expressed as
[0000]
U
_
(
ω
1
)
=
1
+
1
U
x
1
(
ω
1
)
1
+
1
U
x
2
(
ω
1
)
(
31
)
[0037] The bicoherence ratio is defined to estimate the delay between the two signals x 1 (t) and x 2 (t) as an extension of the bispectrum ratio, which is denoted as
[0000]
Λ
x
1
x
2
x
1
(
ω
1
,
ω
2
)
=
b
x
1
x
2
x
1
(
ω
1
,
ω
2
)
b
x
1
x
1
x
1
(
ω
1
,
ω
2
)
(
32
)
[0038] The bicoherence-correlation is computed as follows
[0000]
λ
x
1
x
2
(
τ
)
=
F
-
1
[
∑
ω
2
Λ
x
1
x
2
x
1
(
ω
1
,
ω
2
)
]
(
33
)
[0039] From equation (30) it will be appreciated that the correlated noise has been attenuated and the amplitude effects of the propagation paths in the media have been suppressed. Also, if the signals x 1 (t) and x 2 (t) are measured in similar noise environment, which is usually true, U x1 (w 1 )≈U x2 (w 1 ), then Ũ(w 1 )≈1.
[0040] Another technique that can be used to estimate relative time-delays between waveforms is hybrid beamforming. “Beamforming” refers to the technique of appropriately shifting and summing waveforms acquired by an array to estimate the parameters in a model being fitted to the data. When the time-delays to be estimated are linearly related to sensor position, the estimation procedure is simply called “beamforming,” while in the more general case, when the time delays do not have such a linear relationship, the procedure is called “generalized beamforming. Under suitable hypothesis, generalized beamforming can be justified either as a maximum likelihood estimation of the parameters (see M. J. Hinich and P. Shaman. Parameter estimation for an r-dimensional plane wave observed with additive independent gaussian errors. Ann. Math. Ststist., 43(1):153-169, 1972), or as a maximum of a posterior estimation within a Bayesian framework (see S. Haykin, J. P. Reilly, V. Kezys, and E. Vertatschitsch. Some aspects of array signal processing. IEEE processings of Radar and Signal Processing, 139(1):1-26, 1992). When the model assumed for the data consists of delayed versions of a single unknown waveform, in the presence of added white Gaussian noise, it is a suitable procedure for estimating the waveform together with the unknown delays. The beamforming method considers that the different measurements can be modeled as delayed version of a single unknown signal, corrupted by noise:
[0000] x l ( t )= s ( t−Δτ l (θ))+ n l ( t ), l=1, . . . , M (34)
[0000] where x l (t) denotes the waveform data of receiver l. The waveform delays Δτ l (θ), l=1, . . . , M depend in some fashion on the model parameters θ to be estimated. It is taken that Δτ 1 (θ)=0, using x 1 (t) as the reference waveform, with the remaining M−1 delays taken relative to x 1 (t). A common procedure to fit a model to data of the above form is to choose the parameters θ and signal waveshape s(t) that minimize the squared error between model and data:
[0000]
(
θ
^
1
s
(
t
)
^
)
=
arg
θ
,
s
(
t
)
min
∑
l
,
t
x
l
(
t
)
-
s
(
t
-
Δτ
l
(
θ
)
)
2
(
35
)
[0041] When the noise n 1 (t) is stationary white Gaussian, this is the maximum likelihood procedure for estimating the parameters θ, As Kelly and Levin showed (see E. J. Kelly and M. J. Levin. Signal parameter estimation for seismometer arrays. U.S. ARPA Techinical Report 339, 1964; and M. J. Levin. Least-square array processing for signals of unknown form. The radio and Electronic Engineer , pages 213-222, 1965), this optimization problem is equivalent to beamforming—varying the parameters θ so as to shift and align the waveforms:
[0000]
θ
^
=
arg
max
θ
∑
t
∑
t
x
(
t
-
Δτ
l
(
θ
)
)
2
(
36
)
[0042] By expanding the inner sum, it may be interpreted as varying the parameters θ to shift and sum the cross-correlation between all possible pairs of waveforms:
[0000]
θ
^
=
arg
max
θ
∑
l
,
j
τ
l
,
j
(
Δτ
l
(
θ
)
-
Δτ
j
(
θ
)
)
(
37
)
[0000] where r ij is the cross-correlation between waveforms k and j:
[0000]
τ
lj
(
τ
)
=
∑
t
x
l
(
t
)
x
j
(
t
+
τ
)
_
(
38
)
[0043] Viewing generalized beamforming as shifting and summing pairwise cross-correlation is suggested in earlier work such as R. T. Hoctor and S. A. Kassam, “The unifying role of the coarray in aperture synthesis for coherent and incoherent imaging,” Proc. IEEE, 78(4):735-752, 1990, which uses this view to unify various schemes for array aperture synthesis, while Hahn and Tretter (W. R. Hahn. Optimum signal processing for passive sonare range and bearing estimation. Journal of Acoustic Society of America, 58(1):201-207, 1975; and W. R. Hahn and S. A. Tretter. Optimum processing for delay-vector estimation in passive signal arrays. IEEE Trans. Information Theory , IT-19(5):608-614, 1973) developed an alternative delay estimation procedure based on fitting a regression model to cross-correlations described further in the next section.
[0044] One drawback of the generalized beamforming procedure described above is that it is computationally expensive, particularly if the dependence of delays Δτ l (θ) on the model parameters θ being estimated is complex and if there are relatively many parameters to estimate. Hahn and Tretter propose a scheme for bearing estimation in passive sonar. The problem is to estimate the delays of all waveforms relative to the reference waveform, and the parameters θ to estimate are precisely the delays Δτ l , l=1, . . . , M. Rather than estimate Δτ l directly, Hahn and Tretter suggest first estimating the delays between all possible pairs of waveforms by taking the maxima of the pairwise cross-correlations. The pairwise delays are simply related to the desired model parameters by an overdetermined linear system, which may be solved as the Gauss-Markov estimate of the model parameters, given the pairwise delays. The resulting two-step Hahn-Tretter procedure may be expressed as follows. Denoting e ij as the delay between waveforms i and j, Hahn-Tretter first estimate the pairwise delays e ij via cross-correlation:
[0000]
e
ij
=
arg
max
τ
r
ij
(
τ
)
(
39
)
[0045] The delay e ij between ith and jth waveforms is estimated by cross-correlating waveforms i and j and finding the time index for which the cross-correlation is maximized. Having estimated the pairwise delays e{circumflex over ( ij )}, the next step is to estimate the desired parameters Δτ l . These are linearly related to the pairwise delays:
[0000] e {circumflex over ( ij )}=Δτ i −Δτ j (40)
[0046] The linear relationship between the pairwise delays e{circumflex over ( ij )} and the relative delays Δτi is made more evident by writing the pairwise delays as column vectors e,Δτ respectively: the two are related by matrix A with known entries:
[0000] e=AΔτ (41)
[0047] The convention adopted here for the ordering of the entries of e is that the index pairs i,j are ordered lexically: i<j and j is varied more rapidly than i. For example, the first entry in e,e(1) is the result of the cross-correlations between the first pairs of waveforms, i.e. waveforms 1 and 2; the second entry in e,e(2) is the result of the cross-correlations between the second pairs of waveforms i.e. waveforms 1 and 3. The pairwise delays then follow increasing ordering of waveform indices: Δτ(1) is the relative delays between waveforms 1 and 2, Δτ(2) is the relative, delays between waveforms 2 and 3, . . . etc. The element of matrix A at the (ij,k) position is then
[0000] A ( ij;k )=δ jk −δ ik (42)
[0048] Hahn and Tretter demonstrate that if signal and noise are both assumed to be stationary, Gaussian and uncorrelated, this two-step procedure is optimum in the sense that it achieves the Cramer-Rao bound, and is thus equivalent to maximum likelihood estimation, or beamforming of the full ensemble of waveforms. However, the waveform arrivals are usually not stationary in real applications of sonic logging and hydraulic fracture monitoring. Thus one can expect the true performance of such an algorithm to be somewhat short of the predicted optimum. Another disadvantage of this method is that any gross errors in the pairwise correlations will propagate into the estimates for the relative delays.
[0049] In accordance with an alternative embodiment of the invention a hybrid regression-beamforming procedure is utilized to facilitate time delay estimation. The hybrid regression-beamforming procedure includes beamforming larger size subsets (e.g. triples, quadruples, etc.), and subsequently reconciling the resulting estimates by solving an overdetermined linear system. As the size of the subset being beamformed increases, more waveform averaging is performed, and the resulting estimates are less sensitive to gross errors, although it is recognized that computation complexity also increases. If the number of waveforms is M and the size of the subsets being beamformed is P, then there are ( M P ) subsets to be beamformed, i.e. the number of subsets of size P that can be chosen from the of indices 1 , . . . M, then these subsets can be ordered by lexically ordering the indices. Beamforming each triple of waveforms yields estimates of the P−1 relative delays between the P waveforms. These relative delay estimates can be arranged in an ( M P )*(P−1) matrix, e. The estimates obtained by beamforming subsets of size P are linearly related to the M−1 relative delays Δτ that are thought by matrix A with known entries as before.
[0050] As mentioned above, hybrid regression-beamforming can be carried out for subsets of larger size. Thus, a hierarchy of algorithms is possible, trading off robustness against computational complexity. One systematic way to move through the hierarchy is to start with the simplest procedure, i.e., the Hahn-Tretter regression on pairwise crosscorrelations, and evaluate the model error. A statistical significance test can be performed on the model error to evaluate whether the derived estimates fit the hypothesized model with high probability, as described in H. Scheffe, “ The Analysis of variance ,” John Wiley and Sons, 1959. If least-squares is the criterion, then a χ 2 test is appropriate, and if semblance is optimized then a non-central β test is appropriate (see E. Douze and S. Laster, “Statistics of semblance,” Geophysics, 44:1999-2003, 1979). If the model error is too high, then subsets of size 3 can be beamformed. Subsets of increasing size maybe used to derive estimates, until the model error is acceptably low.
[0051] In accordance with another alternative embodiment of the invention the hybrid regression-beamforming procedure is combined with high order statistics to facilitate time delay estimation. In practice, it means that rather than using the correlation to obtain the delay estimate between pairs (see equation 38), the delay estimated will be computed using high order statistics as already explained above. Since the high order statistics is demonstrated to be more effective at estimating the corresponding delays between pairs of waveforms as shown previously, combing both approached will provide more robust results. Further, this combination of methods will not significantly increase computational requirements.
[0052] A statistical procedure may also be employed to detect the absolute time of arrival of a waveform. Absolute time detection helps to enhance fracture localization. Perhaps the most common technique for computing first arrival of an event is the Energy Ratio Approach, which is based on the ratio between the instantaneous trace energy normalized by the cumulative trace energy. This is computed as follows:
[0000]
Ef
(
t
)
=
∫
τ
τ
+
T
x
2
(
t
)
t
∫
0
T
x
2
(
t
)
t
(
43
)
[0000] where T is the width of the running window used to compute the instantaneous energy. Nevertheless, the normalization by the cumulative energy will penalize the late arrival. To avoid this kind of problem another factor can be added to the denominator:
[0000]
Ef
(
t
)
=
∫
τ
τ
+
T
x
2
(
t
)
t
∫
0
τ
x
2
(
t
)
t
+
α
∫
0
L
x
2
(
t
)
t
(
44
)
[0000] where L is the length of the trace considered. The coefficient α is in the range of [0,1]. Such a detector for first motion is satisfactory under certain conditions, but not in the presence of high noise levels. Similar to the energy function indicator, another commonly used first motion detector, which just computes the energy before and after the point of interest inside a window of width T, is denoted as follows:
[0000]
Er
(
t
)
=
∫
τ
τ
+
T
x
2
(
t
)
t
∫
τ
-
T
T
x
2
(
t
)
t
(
45
)
[0053] Similar to the energy function, a normalization factor can be introduced for the energy ratio indicator, to obtain the following indicator:
[0000]
Er
(
t
)
=
∫
τ
τ
+
T
x
2
(
t
)
t
∫
τ
-
T
T
x
2
(
t
)
t
+
α
∫
0
L
x
2
(
t
)
t
(
46
)
[0054] An extension of this method can be obtained by using the product of the energy ratio and energy function indicators. However, these methods are also degraded in the presence of relatively high noise levels.
[0055] In accordance with one embodiment of the invention a statistical detection technique is used to estimate first arrival time in the presence of high noise. The goal is to detect a point before which the signal is considered as noise and after which the signal is considered the signal of interest in order to, for example, detect the first arrival of the various events present in HFM data in order to properly estimate the absolute delay estimate across the array. A procedure is been described in H. P. Valero, M. Tejada, S. Yoneshima, and H. Yamamoto, “High resolution compressional slowness log estimation using first motion detection,” SEG Extended Abstract, 75 th Annual Meeting, Houston, Nov. 6-11, 2005, to detect first motion of a single trace using statistical signal processing. However, the HFM data is more complicated due to corruption by various type of noise and in addition. It would also be advantageous to use the same algorithm to detect P and or S arrival. It is reasonable to assume that the spectral characteristics before and after the first break are different. From the point of view of time series modeling, this means that the models for time series before and after the arrival of a compressional, for example, are quite different. Since the spectrum of the time series can be well expressed by an appropriate AR model, it is reasonable to use an AR model for each time series, i.e. for the time series before and after the first break. In this case it is assumed that these two series can be considered as locally stationary AR models. Note that this methodology does not make any assumption about the type of component or signal for which the first arrival is to be detected. The methodology is not limited to the detection of a compressional component and can be applied to other detection problems.
[0056] The principle of the statistical method is that before the first break, T, of an event, u, the time series is considered as noise, whereas after the first break the signal of interest is considered as being present. The problem of detecting the first break can therefore seen as detecting a change in the AR model. Defining x ml (t); m=1, . . . , N r ; l={x, y, z}; t=1, . . . , N, a windowed time series containing a signal of interest, the noise model can be written as
[0000]
x
l
=
∑
i
=
1
p
1
A
i
1
x
l
-
1
+
ɛ
l
1
;
l
=
1
,
…
,
T
(
47
)
[0057] and the signal model as
[0000]
x
l
=
∑
i
=
1
p
2
A
i
2
x
l
-
1
+
ɛ
l
2
;
l
=
1
,
…
,
N
(
48
)
[0000] where p j is the model order of the autoregressive model, A ji is the autogregressive coefficient matrix of the AR model of dimension k×k, where k is equal to the number of components, i.e., 3 in general or 2 if one of the component cannot be used. ε ij =noise(C) are uncorrelated random vectors with mean zero and covariance C j ; j=1, 2. Assuming the arrival time and the orders of the autoregressive models, p 1 and p 2 are know, the distribution of the time series can be written as follows:
[0000]
x
l
j
~
N
(
∑
i
=
1
p
j
A
ij
x
l
-
1
,
C
j
)
(
49
)
[0000] where j=1 if l=1, . . . , T and j=2 if l=T+1, . . . , N. The log likelihood of this problem can be written as
[0000]
LL
(
A
1
,
A
2
,
C
1
,
C
2
)
=
-
1
2
{
(
N
-
p
1
)
log
2
π
+
(
T
-
p
1
)
log
C
1
+
}
∑
l
=
1
+
p
1
T
ɛ
l
1
†
C
1
-
1
ɛ
l
1
+
(
N
-
T
)
log
C
2
+
∑
l
=
1
+
T
N
ɛ
l
2
†
C
2
-
1
ɛ
l
2
.
(
50
)
[0058] The maximum likelihood of A ij and C j (i=1, . . . N) are given by maximizing the previous equation. It also possible to calculate the parameters for the signal and noise model by minimizing the following equations:
[0000]
(
A
1
^
,
C
1
^
)
=
arg
A
1
,
C
1
min
[
(
N
-
T
)
log
C
1
+
∑
l
=
1
+
T
N
ɛ
l
2
†
C
1
-
1
ɛ
l
2
]
[0000] for the noise model while for the signal model
[0000]
(
A
2
^
,
C
2
^
)
=
arg
A
2
,
C
2
min
[
(
N
-
T
)
log
C
2
+
∑
l
=
1
+
T
N
ɛ
l
2
†
C
2
-
1
ɛ
l
2
]
.
[0059] Knowing these parameters, it is possible to compute the Bayesian Information Criterion (BIC) as:
[0000] BIC=−2 LL ( Â 1 , Ĉ 1 , Â 2 , Ĉ 2 )+ k log′ [ N].
[0060] The first break is then estimated at the minimum of the BIC function.
[0061] While the invention is described through the above exemplary embodiments, it will be understood by those of ordinary skill in the art that modification to and variation of the illustrated embodiments may be made without departing from the inventive concepts herein disclosed. Moreover, while the preferred embodiments are described in connection with various illustrative structures, one skilled in the art will recognize that the system may be embodied using a variety of specific structures. Accordingly, the invention should not be viewed as limited except by the scope and spirit of the appended claims.
|
Automatic detection and accurate time picking of weak events embedded in strong noise such as microseismicity induced by hydraulic fracturing is accomplished by: a noise reduction step to separate out the noise and estimate its spectrum; an events detection and confidence indicator step, in which a new statistical test is applied to detect which time windows contain coherent arrivals across components and sensors in the multicomponent array and to indicate the confidence in this detection; and a time-picking step to accurately estimate the time of onset of the arrivals detected above and measure the time delay across the array using a hybrid beamforming method incorporating the use of higher order statistics. In the context of hydraulic fracturing, this could enhance the coverage and mapping of the fractures while also enabling monitoring from the treatment well itself where there is usually much higher and spatially correlated noise.
| 6
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an apparatus for receipt, retaining, sterilization, disinfecting and disbursing of bank notes, more specifically to a currency handling device such as a cash box comprising an automated, internal sterilization and disinfecting processes.
[0003] 2. Description of the Related Art
[0004] Proper receipt and handling of bank notes, particularly currency, has generally tended toward cash box type registers systems. Many systems have been developed for receipt, retaining and disbursal of currency, including such features as initiating a dispensing operation wherein bills sorted in money cases and a money receiving and disbursing box. Such systems may include automated pick-out devices for removal of the bills in the money cases where a quantity of the bills in the money cases is more than a predetermined value.
[0005] Further devices include cash transaction machines which include a sterilizing unit for sterilizing bills by heat, wherein the heating temperature of the sterilizing unit is maintained and detected by a sensor and maintained in a specified range. discloses a cash transaction machine performs receiving and/or paying transactions of bills by manipulation of a user, transfers bills between a receptacle where bills are paid in and out and a storage where bills are stored, and by using a sterilizing unit for heat-sterilizing bills being transferred at a specified temperature range and a specified time period.
[0006] Further disclosed are mechanisms for feeding a lengthwise oriented piece of paper dollar currency, or the like, in a C-shaped feed path and mounted on rollers about a centrally located ultraviolet source, which contributes to the sterilizing of the bill. Still further concurrent systems include a paper sterilization system comprising a chamber having one wall with an input slot and another wall with an output slot, a conveyor system comprising two co-acting belts in facing contact. While others disclose a method of sorting mail according to the invention includes the steps of receiving a plurality of first mail pieces of unknown origin in a first apparatus for bulk processing of the mail pieces, processing the mail pieces in the first apparatus by one of testing the mail pieces to determine if a potentially dangerous microorganism is present, sterilizing the mail pieces to destroy microorganisms on mail pieces, or both.
[0007] As is apparent, cleaning, washing, pressing of banknotes, particularly paper money is generally harmful and may reduce both the grade and the value of any note. Most assuredly, a washed or pressed note will lose its original sheen and its surface may become lifeless and dull. The existing defects within a note, such as folds and creases, may not necessarily be completely eliminated through washing or pressing and telltale marks can easily be detected under proper lighting conditions. Furthermore, carelessly washed notes may possess white streaks where the folds or creases existed. Thus, processing of a note which started out with a rating of Extremely Fine would certainly reduce the note at least one full grade.
[0008] Additionally, glue, tape, or pencil marks may often be successfully removed. While such removal will produce a clean surface, it will improve the overall appearance of the note without concealing any of its defects. Under such circumstances, the grade of the note may also be improved. Also, the words “pinholes”, “staple holes”, “trimmed”, “writing on face” and “tape marks” and the like should always be added to the description of a note as it is realized that certain countries routinely staple their notes together in groups before issue. In such cases, the description can include a comment such as “usual staple holes” or something similar in order to indicate to those would not otherwise know that this specific note cannot be found otherwise.
[0009] Thus, unfortunately, once currency is continually defiled, there exists no straightforward way to clean paper currency as conventional manners including utilization of soap and water, will not penetrate the surface of the bill.
SUMMARY OF THE INVENTION
[0010] The instant device and system, as illustrated herein, is clearly not anticipated, rendered obvious, or even present in any of the prior art mechanisms, either alone or in any combination thereof. One object of the present apparatus is to provide a multi-configuration apparatus for receipt, retaining, sterilization, disinfecting and disbursing of bank notes, more specifically to a currency handling device such as a cash box comprising an automated, internal sterilization and disinfecting processes.
[0011] A further objective of the instant design is to introduce a stand alone, or retrofitted cash box that incorporates interior mounted ultra violet light sterilization and integrally disposed aerosol disinfectant release systems comprising automated actuation upon closing of the cash drawer, in order to reduce the amount of germs and bacteria found on currency both paper and coins at points of currency transaction (POS point of sale).
[0012] The present system relates to the sterilization of currency within a cash box, via the utilization of ultraviolet sterilization and disinfectant aerosol release. The system thus reduces the transmission of germs and bacteria at point of currency exchange during transactions. It is known that ultraviolet irradiation is successful in the elimination of germs and bacteria as applied in Laundromats (dry cleaning), ultraviolet sterilization for barbers tools, manicure equipment and dental tools. These applications have not been introduced to the cash register or ATM which is the main point of transfer for currency between people.
[0013] Broadly stated, the instant system provides a replacement for the standard cash box and cash drawer, which incorporates ultraviolet sterilization/irradiation and disinfectant expulsion within the cash drawer, once the drawer is closed and prior to re-opening of the draw. More specifically it is an object that provides-sterilization for use at a check out location for any retail location or place of currency exchange of which the currency can be exposed to sterilization in turn reducing the amount of germs and bacteria commonly found on currency and in turn reducing the transfer of germs between people.
[0014] Regarding usage with existent systems for currency storage and disbursal, such as cash registers, a new cash drawer will be supplied with each retro-fit for cash registers. This drawer may comprise a slightly greater height than drawers normally fitted in today's market-place. Located within the retrofitted drawer apparatus will be a metal frame that will be inserted secured to the inside of the drawer. This frame will act as the mounting points for either or both of an ultra violet introduction system and a disinfectant application system. The frame will act as wire management as well. Once the drawer is closed a pin actuator will turn on sterilization process and be controlled via a timer. The drawer kit/retro kit will incorporate a new cash drawer that is ventilated and transparent.
[0015] Further, as purpose of this project is to develop comprehensive currency sterilization at point of sale, point of sale is defined, but not limited to, cash registers, automated teller machines (ATM's), banks or other locations of currency transactions and transfers. Sterilization of currency prior to forwarding of said monies to another person or entity can help reduce transmission of known bacteria's, germs and other socially transferred disease. In effect we could lower potential spreading of common colds, viruses and socially common illnesses like H1N1.
[0016] Additionally, in one embodiment a new cash drawer comprised of high density poly propylene plastic and be ventilated on all areas similar to a strainer. This design would allow for airflow thus reducing any heat buildup and allowing for cross penetration. Additionally defined are embodiments of slim profile UV lamp system that could be mounted internally, thus enveloping the cash drawer with light rays. Additionally, as the currency on top of the drawer is the next to be distributed, a downward lamp would be of the utmost importance, especially for application similar to an ATM usage.
[0017] The other method of sterilization, which would employ a pressurized burst of common household disinfectant, which may also utilize booster fans for greater circulation. A simple pin actuator at the drawer closing point would act as start point of sterilization.
[0018] Phase two of product development would be the development, in conjunction with the largest manufacturer of cash registers and ATM's newly designed that would be specifically built two incorporate one or two of the technologies discussed above. Between the Severe Acute Respiratory Syndrome (SARS) and H1N1 outbreaks, a greater awareness of human hygiene and following of simple procedures which may save lives people throughout the world have become made us all more hygiene-conscious.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0019] As illustrated in FIG. 1 , the instant system comprises a tube frame disposed to fit within the actual cash box of a register and further illustrates the disinfectant system which incorporates a series of nozzles disposed on the side walls of the cash box;
[0020] FIG. 2 a illustrates the support frame disposed to retain the ultraviolet (UV) light panel array;
[0021] FIG. 2 b illustrates the top panel which houses the Ultraviolet array or UV introduction system and the UV introduction system which comprises a series of bulb holders, mounted on a substantially horizontally disposed frame;
[0022] FIG. 3 illustrates the ultraviolet (UV) light panel array placed within the upper section of the support frame disposed to retain the ultraviolet (UV) light panel array.
[0023] FIG. 4 illustrates an internal view of one embodiment of the cash box mechanism utilizing an additional embodiment of UV lighting, a UV flex lighting fixture mounted on top of the cash box;
[0024] FIG. 5 illustrates the cash drawer mechanism, illustrating the paper currency containment chambers and the coinage containment chambers which double as and the divider walls; and,
[0025] FIG. 6 illustrates a bottom cash box UV lighting panel to be utilized with the embodiment exemplified in FIG. 5 .
DETAILED DESCRIPTION OF THE INVENTION
[0026] As illustrated in FIG. 1 , instant invention comprises a tube frame 10 , disposed to fit within an actual cash box 11 of an existing cash register system, and thus the cash box acts as an outer casing. In one embodiment, the dimensions may include a height of 3.5 and inches, a length of 15.75 inches and a width of 15.5 inches. This system would be enclosed within a cash box 11 of a height 3 and 15/16, width of 16 and ⅛ and a length of 16 and ⅜. The tube frame 10 may be disposed to move in and out of the cash box 11 along a pair of running tracks 19 a - 19 b via wheels, bearings or any other slidably disposed mechanism as regularly used in the cash register or other such arts.
[0027] FIG. 1 additionally illustrates an embodiment of the disinfectant system wherein there exists a series of nozzles 12 . At least three nozzles 12 should be utilized, one for each of the three side walls 13 of the cash box 11 , wherein the nozzles are in fluid communication through a system of tubing 14 and disinfectant fluid is supplied through a supply reservoir apparatus 15 as known in the fluid arts. Additional nozzles 12 may be utilized for each wall and thus multiples of 3, including 6, 9 or 12 nozzles 12 , may be utilized. A bladder system or a small pump system, as known in the fluid arts, may be utilized within the supply and reservoir apparatus 15 in order motivate the fluid through the tubing 14 .
[0028] The disinfectant system will be triggered upon opening and closing of the drawer, by a pin actuator 18 , or other similar mechanism, wherein upon depression of the pin actuator 18 , an attached check valve mechanism, as known in the fluid arts, which is in fluid communication with the supply reservoir apparatus 15 , is open to allow a metered flow of disinfectant, as the tube frame 10 moves in and out of the cash box 11 on the running tracks 19 a - 19 b.
[0029] FIG. 2 further illustrates the tube frame 10 and specifically the receiving mechanisms 17 a - 17 d , for attachment of the ultraviolet (UV) light panel 20 . Two of these panels should be employed as a top panel 20 a and a bottom panel 20 b . FIG. 2 further illustrates the top panel or ultraviolet (UV) light panel 20 which comprises at least a bulb holder system 21 comprising at least one bulb holder 21 a , mounted on at least two horizontal disposed tubes 22 a and 22 b or support beams, the horizontally disposed tubes mounted at opposing ends of the on either side and said panel 20 . The horizontal support beams 22 a and 22 b maybe composed of any substantially non flammable material including steel, composite materials or any combination thereof. Additionally, the horizontally disposed tubes should be connected by at least two vertically disposed tubes 29 a and 29 b . Extending from the horizontal tubes 22 a and 22 b may be a series of mating protrusions 23 a - 23 d , disposed for attachment to steel tube frame 10 to mate with the corresponding receiving mechanisms 17 a - 17 d . The mating protrusions 23 a - 23 d , and the corresponding receiving mechanisms 17 a - 17 d , may be constructed as male to female mating systems.
[0030] Additionally, the ultraviolet (UV) light panel 20 may comprise a set of four inch (4″) uv tubes 24 , in one embodiment, five (5) four inch (4″) UV tubes may be utilized. And, the ultraviolet (UV) light panel 20 may comprise a set of two inch (2″) UV tubes 26 , in one embodiment five (5) four inch (2″) UV tubes may be utilized. The ultraviolet (UV) light panel 20 may also comprise a set of corresponding 4″ UV bulb adapters for the 4″ tubes and a set of 2″ UV bulb adapters for the 2″ UV tubes.
[0031] Further, the ultraviolet (UV) light panel 20 may comprise a power wire 27 and a corresponding lead to a power supply such as a one hundred and ten (110) volt source. The frame may be of a modular construction, or may also be composed of numerous pieces welded or formed together. The ultraviolet (UV) light panel 20 may be composed of any such material that can sufficiently meet the strength and heart tolerance requirements. Thus, numerous metals and composite material configurations, and combinations thereof, may be envisioned.
[0032] Much like the disinfectant system, the ultra violet panel may be designed in communication with a trip switch to power off and on with opening and closing of the drawer respectively, as know in the art. In that respect, both the ultraviolet and disinfectant systems may be electrically configured to be constantly running during register operation.
[0033] FIG. 3 illustrates the support frame 30 for the ultraviolet (UV) light panel array or system 20 . The support frame 30 comprises a top panel 31 , at least two frame upright backs (left and right) 32 , at least two frame upright fronts (left and right) 33 , a top bar 34 , lower bar 35 , the ultraviolet (UV) light panel 20 may be hung from both the upper and lower frame (as shown).
[0034] Additionally, FIG. 4 illustrates an internal view of one embodiment of the cash box mechanism utilizing an additional embodiment of UV lighting, a UV flex lighting fixture 41 , mounted on top of the cash box.
[0035] Further, FIG. 5 illustrates the cash drawer mechanism 50 , wherein the cash drawer may be comprised of a molded design, which may be composed of transparent poly-propylene or any such polymeric material, and is designed to be ventilated to allow for increased exposure to airflow for the drying process. Thus, substantially all areas of the cash drawer mechanism 50 , including the cash box side walls 51 , may be perforated for increased exposure to disinfectant materials and for increased airflow. As an example and not meant to limit the material utilized, the cash drawer of the system may comprise materials such as clear poly propylene and/or perforated plastic to allow for greater surface exposure and currency desiccation.
[0036] Further illustrated, the paper currency containment chambers 52 may be physically defined be divider walls 53 , and coinage may be stored within these divider walls 53 . Again, both the containment chambers 52 and the divider walls 53 may also be perforated. The cash drawer mechanism 50 will be inserted underneath the UV light panel 20 .
[0037] Additionally, it is envisioned to incorporate a front panel 54 for retaining currency in a proper position for cleaning, disinfection and latter currency disbursal. The front panel 54 may also be perforated and may also contain a UV strip 55 . Included as well may be at least one footer mechanism 56 , disposed at each lower side of the four corners of the cash drawer mechanism 50 . The plurality of footer mechanisms 56 is designed to keep the cash drawer mechanism 50 from contacting the register floor and thus increase airflow. Thus, the plurality of footers 55 will afford the system the feature of bottom up sterilization.
[0038] FIG. 6 illustrates a bottom cash box UV lighting panel 60 to be utilized with the embodiment exemplified in FIG. 5 . The slim panel may be attached to interior of cash box to make a bridge like passage. Additionally, the ultraviolet (UV) light panel 60 may comprise a set of four inch (4″) UV tubes 64 , in one embodiment, five (5) four inch (4″) UV tubes may be utilized. And, the ultraviolet (UV) light panel 60 may comprise a set of two inch (2″) UV tubes 66 , in one embodiment five (5) four inch (2″) UV tubes may be utilized. The ultraviolet (UV) light panel 60 may also comprise a set of corresponding 4″ UV bulb adapters for the 4″ tubes and a set of 2″ UV bulb adapters for the 2″ UV tubes.
[0039] There has thus been outlined, rather broadly, the more important features of the portable electronics tester in order that the detailed description thereof that follows may be further understood, and in order that the present contribution to the art may be better appreciated. There are additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto.
[0040] In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
[0041] These together with other objects of the invention, along with the various features of novelty, which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be made to the accompanying drawings and descriptive matter in which there are illustrated preferred embodiments of the invention.
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A stand alone or retrofitted cash box that incorporates inner mounted ultra violet light sterilization and aerosol disinfectant release systems comprising automated actuation upon closing of the drawer, to reduce the amount of germs and bacteria found on currency both paper and coins at points of currency transaction. The retrofitted cash drawer component of the system comprises a perforated design to allow for greater surface exposure and currency desiccation quality.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a non-provisional of and claims priority to U.S. Provisional Patent Application No. 61/570,802, filed on Dec. 14, 2011, the entire contents of which are hereby incorporated by reference.
BACKGROUND
This specification relates to detecting compromised resources.
Internet search engines aim to identify resources (e.g., web pages, images, text documents, multimedia context) that are relevant to a user's needs and to present information about the resources in a manner that is most useful to the user. Internet search engines return a set of search results in response to a user submitted query.
Resources can be modified by third parties without permission. For example, a third party can replace original content of the resource with spam content. These resources can be referred to as compromised or defaced resources. A search result to a defaced resource may be less relevant to a user's needs.
SUMMARY
This specification describes technologies relating to detecting compromised resources.
The system described can detect a modified resource by applying the resource to three stages. First, the system extracts signals from the resource to determine whether the resource may be impermissibly modified. Second, the system merges the resource with selected previous versions of the resource. Third, the system compares a most recent version of the resource to one or more threshold criteria, which indicate the resource may have been impermissibly modified. If the resource satisfies the one or more thresholds, the system determines that the resource is compromised.
In general, one innovative aspect of the subject matter described in this specification can be embodied in methods that include the actions of receiving a resource; determining the resource is tainted based on one or more indications that the resource has been compromised; merging the tainted resource with previous versions of the resource that were tainted to generate a most recent tainted resource; determining the tainted resource is compromised by analyzing attributes of the most recent tainted resource that satisfy one or more threshold criteria that indicate the resource has been compromised; and identifying the tainted resource as compromised. Other embodiments of this aspect include corresponding systems, apparatus, and computer programs, configured to perform the actions of the methods, encoded on computer storage devices.
These and other embodiments can each optionally include one or more of the following features. Receiving a second resource; determining the second resource is tainted based on one or more indications that the second resource has been compromised; merging the second tainted resource with previous versions of the second resource that were tainted to create a most recent second tainted resource, wherein all previous versions of the second resource are tainted; and discarding the second tainted resource. Receiving a second resource; determining the second resource is untainted based on one or more indications that the second resource has not been compromised; merging the second untainted resource with previous versions of the second resource that were untainted to create a most recent second untainted resource, wherein all previous versions of the second resource are untainted; and discarding the second untainted resource.
These and other embodiments can each optionally include one or more of the following additional features. Adding the tainted resource identified as being compromised to a list of compromised resources. The previous untainted version of the resource can exist longer than a predetermined time after an initial index date. The most recent second tainted resource can be a web page, the web page having spam words in the Uniform Resource Locator of the web page. The most recent second tainted resource can have user generated content. The resource can be a web page, wherein the one or more indications that the resource has been compromised include one or more parameters selected from a number of words in a title of the page, metadata, content of the page, location of words on the page, repeated percentage of words, forward links on the page, content of pages the forward links points to, back links on the page, content of pages the back links point from, existence of user generated content, domain type, or language of the page. The one or more threshold criteria can be based on the one or more indications that the resource has been compromised. The resource can include a web page, image, text document, or multimedia.
In general, another aspect of the subject matter described in this specification can be embodied in methods that include the actions of receiving a resource; determining the resource is tainted based on one or more indications that the resource has been compromised, the resource being medically related; merging the tainted resource with previous versions of the resource that were tainted to create a most recent tainted resource; merging previous versions of the resource that were untainted to create a most recent untainted resource; determining the tainted resource is compromised by analyzing differences between the most recent untainted resource and the most recent tainted resource that satisfy one or more threshold criteria that indicate the resource has been compromised; and identifying the tainted resource as compromised.
In general, another aspect of the subject matter described in this specification can be embodied in methods that include the actions of receiving a search query; obtaining a plurality of search results responsive to the search query; determining that a first search result in the plurality of search results identifies a resource that exists in a collection of compromised resources; and identifying the first search result as being potentially compromised.
These and other embodiments can each optionally include one or more of the following additional features. Providing one or more search results, wherein the first search result includes a warning message indicating that the resource is potentially compromised. Sending a notification to a manager of the resource, wherein the notification indicates the resource is compromised
Particular embodiments of the subject matter described in this specification can be implemented so as to realize one or more of the following advantages. The system can automatically identify a resource as modified. The system can extract numerous signals from the resource to determine the likelihood that a given resource has been modified. Another advantage is that the system can consider multiple previous versions of the resource to increase the accuracy of identifying whether the resource is modified. Yet another advantage is that the system can accurately detect modifications of various types of resources including educational or governmental web pages. Because some resources may be impermissibly modified to include unwanted terms, the system can accurately detect a modification even if the original unmodified resource includes terms similar to the unwanted terms. The unwanted terms may include, for instance, medical terms, or others terms concerning pornography or other products. Furthermore, the owner of the resource does not have to monitor the resource because the system can notify the owners if the resource is modified. Yet another advantage is that the system can include an interstitial warning about the modified resource to those that wish to access the modified resource. For example, if a search engine implements the system to warn users of compromised web pages in search results, this warning allows users to avoid selecting the compromised web pages that are returned as search results.
The details of one or more embodiments of the subject matter described in this specification are set forth in the accompanying drawings and the description below. Other features, aspects, and advantages of the subject matter will become apparent from the description, the drawings, and the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of an example system that detects compromised resources.
FIG. 2 is a flow chart illustrating example method for detecting compromised resources.
FIG. 3 is a diagram illustrating an example extraction stage of a classifier.
FIG. 4 is a diagram illustrating an example merging stage of a classifier.
FIG. 5 is a diagram illustrating an example comparison stage of a classifier.
FIG. 6 is a flow chart showing an example process for identifying compromised search results.
FIG. 7 is a diagram showing an example search results page including a warning displayed within search results.
Like reference numbers and designations in the various drawings indicate like elements.
DETAILED DESCRIPTION
FIG. 1 is a schematic illustration of an example system 100 that detects compromised resources. The resources can include, for example, web pages, images, text documents, or multimedia context. The system 100 includes a data processing apparatus 102 and an index 108 . The data processing apparatus 102 and index 108 can communicate with each other through a network 106 . In some implementations, data processing apparatus 102 are servers e.g., rack-mounted servers or other computing devices. The servers can be in the same physical location (e.g., data center) or they can be in different physical locations. The servers can have different capabilities and computer architectures.
The data processing apparatus 102 includes a classifier 104 . The classifier 104 can detect resources that have been compromised, in particular, compromised web pages, as will be further described below. The index 108 can be a database created by crawling web resources, which the classifier 104 processes to identify uncompromised resources. The index 108 can also be stored across multiple databases. In some implementations, the index 108 stores web pages, representations of web pages, or references to web pages identified as being untainted or uncompromised. In some implementations, the index 108 stores multiple versions of resources. In some implementations, multiple versions of resources are stored in a separate database or index. Newly retrieved (e.g., crawled) resources identified as potentially being compromised can be compared with a corresponding untainted or tainted version in the index 108 . A newly retrieved resource can be a candidate compromised resource, which can be designated as either untainted or tainted. An untainted version of the resource is one which the system believes has not been compromised. A tainted version of the resource is one which the system believes may have been compromised. For example, for a web page, the system compares a candidate compromised web page to untainted or tainted versions of the web page that are stored in the index. Also, the index 108 can be stored in an electronic file system, a distributed file system or other network-accessible persistent storage which can store information on computer-readable storage media.
FIG. 2 is a flow chart illustrating example method 200 for detecting compromised resources. For convenience, the method 200 will be described with respect to a system having one or more computing devices that performs the method 200 . For example, the system can be the system 100 described with respect to FIG. 1 . In other words, the system can determine whether a candidate compromised resource is compromised by applying the method 200 . The compromised resource can be, for example, a compromised web page. A page can be considered compromised if original content on the page has been replaced by a third party with unauthorized content. An example of a compromised web page can include a web page, e.g., a university's home page, whose content was impermissibly modified (or “hacked”) to display links to commercial sites offering to sell prescription drugs or other products. For convenience, the method will be described with respect to a web page resource.
To determine whether a candidate compromised version of a page is compromised, the system receives a collection of page versions 202 corresponding to the page. The collection of page versions can represent or include multiple versions of the page that have been indexed over time and also includes the candidate compromised page. The collection can be received from various sources including an index of Internet web pages or an external database. After receiving the collection of page versions, the system can use a classifier to ultimately determine whether the candidate compromised version of the page has been compromised. The classifier processes the collection of page versions in 3 stages: 1) extraction 204 , 2) merging 206 , and 3) comparison 208 . The extraction stage will be described with respect to FIG. 3 . The merging stage will be described with respect to FIG. 4 . The comparison stage will be described with respect to FIG. 5 .
FIG. 3 is a diagram illustrating an example extraction stage 300 of the classifier. As mentioned above, the system receives a collection of page versions 302 and inputs it into a classifier 304 . The system categorizes each page version, including the candidate compromised page, as belonging to either untainted or tainted categories. An ‘untainted’ designation indicates the page has not been compromised. A ‘tainted’ designation indicates the page may or may not be compromised, signaling the classifier to perform additional operations to determine whether the page has been compromised as will be further described below. Additionally, a third category or, alternatively, a sub-category of untainted can include untainted educational as will be further described below. Other categories or sub-categories can include government pages, organizational pages, or any other pages that are commonly targeted by hackers.
The system extracts signals from each page. These extracted signals can include information about potential spam words and potential spam backlinks. Spam words can, for instance, include particular words or phrases that are commonly associated with spam or other unwanted content. In some implementations, spam words can include the names of prescription drugs that are usually targeted by spammers, for example, to promote unauthorized prescription drug sales. An example of an extracted signal can be a number of identified spam words. Another example of an extracted signal can be a number of spam backlinks. Spam backlinks can be, for instance, incoming links to each page, where the incoming links are from other pages commonly associated with spam content.
These signals can be used to categorize the page as untainted or tainted. The number of spam words in the page can be determined by searching the title, content, and metadata of the page. In some implementations, a list of spam words is retrieved from a database. The system then compares the words from the list of spam words to the words in the page. Even if some words in the page match some words from the list of spam words, the page may not be considered tainted. The system can still consider whether the number of matches satisfies one or more threshold criteria as will be further described below.
A page can be categorized as untainted if it contains fewer spam words than a threshold of a number of spam words in the page. The threshold can be any suitable value, e.g., 1, 5, 10, 50, 100, 500, or 1000 . . . . A page can also be categorized as untainted if it contains fewer spam backlinks than a threshold of a number of spam backlinks in the page. The threshold can be any suitable value, e.g., 1, 5, 10, 50, 100, 500, or 1000. In some implementations, spam backlinks of a page are incoming links to the page from pages that mention names of prescription drugs or other spam words. The system can also consider signals including the actual content of the page, the location of spam words in the page, the language of the page, forward links (i.e., links on the page that point to another page), age of the page, source of the page, frequency of top keywords, or user generated content (e.g., forum comments or blog comments).
A page can be classified as tainted if it satisfies certain thresholds, e.g., whether there are a threshold number of spam words in the page or a threshold number of spam backlinks. Both thresholds can be any suitable value, e.g., 1, 5, 10, 50, 100, 500, or 1000. In some embodiments, additional categories or sub-categories can be considered or evaluated. For instance, the category of educational untainted can include pages with an .edu domain that do not have spam words in the page, but may have some spam backlinks pointing to the page. While most hacked pages are edited by site administrators to remove unwanted third-party content such as spam words, backlinks containing spam can still remain pointing to the pages. Therefore, creating an additional category for “educational untainted” sites can increase the accuracy of identifying compromised resources. In some alternative implementations, to increase accuracy, the system can consider or evaluate additional categories similar to the “educational untainted” category, e.g., categories for pages having a .gov domain, .org domain, or other domains that have historically been highly targeted by hackers.
FIG. 4 is a diagram illustrating an example merging stage 400 of the classifier. In some implementations, previous versions of the page may be either untainted or tainted. Some versions may be duplicates of each other while other versions may have only slight variations of each other. For each page in the collection of page versions, whether a duplicate or a variant, the system categorizes the page as untainted or tainted 402 . After categorizing each page version based on the signals described above, the system merges pages of the same category together. In some implementations, the system merges representations of, or references to, pages. By merging references, the system can remove references pointing to a duplicate page. The system creates a collection of untainted pages and merges each page, or each reference to a page, categorized as untainted into the collection of untainted pages 404 . Similarly, the system also creates a collection of tainted pages and merges each page, or each reference to a page, categorized as tainted into the collection of tainted pages 406 .
In some implementations, following the merge, the system retains the most recent untainted page from the collection of untainted pages. The classifier then inputs the most recent untainted page and the candidate compromised page (which can be designated as untainted or tainted) to the comparison stage. In some implementations, there will only be a merged collection of untainted pages and no merged collection of tainted pages. In this case, the classifier will skip the rest of the process because the candidate compromised page is untainted and has not been compromised. In some implementations, there will only be a merged collection of tainted pages and no merged collection of untainted pages. In this case, the classifier will also skip the rest of the process because the candidate compromised page, although tainted, has not been compromised. Because this page has never been untainted, the page has always contained spam and has not been compromised from an untainted version.
FIG. 5 is a diagram illustrating an example comparison stage 500 of the classifier. The classifier first subjects the candidate compromised page to a series of tests 514 . If the page passes the tests, the classifier continues to compare the page to various thresholds. If the page does not pass the series of tests, the page can be discarded 510 . A discarded page is determined to not be compromised, but it maintains its designation as tainted in the index. For example, if the number of spam words in the page's Uniform Resource Locator (URL) reaches a threshold, the page can be discarded. The system discards this type of page because URLs can, in some instances, be more difficult to compromise. Therefore, if a page has a URL with spam words, the owner of the page may have approved the URL and the page was less likely to have been compromised.
In another example, if the spam words appear as user generated content, the page may be discarded. User generated content may appear on blogs, guest books, forums, or any other type of page that allows user input. In some embodiments, the system can discard this type of page because spam words in the form of user generated content are less indicative that the page has been compromised. The system may, for instance, assume the owner of the page intentionally provided Internet users the ability to add content onto the page, even if the content contains spam words.
In some embodiments, if the date of the most recent version of the page and the date of the first indexed version of the page are both within a threshold period of time, the page can be discarded. In some implementations, this threshold time period can be a day, 48 hours, a week, three weeks, five weeks, two months, or six months. The system may discard this type of page because the page has too few previous versions to compare to.
In some implementations, a spam word may be considered ambiguous if it can represent a person's name or other proper noun. In this case, pages with spam words that may be confused for a person's name or other proper nouns can be discarded. In an effort to minimize false alarms, the system may err on the side of caution when identifying candidate compromised pages as compromised.
After a page passes initial tests 514 , the classifier compares the candidate compromised page 502 to numerous thresholds 506 . In some implementations, the latest untainted version 504 can be used when the candidate compromised page 502 can be a page having unwanted terms. For example, the page can be a medical page. In some alternative implementations, the candidate compromised page 502 includes other content. To pass initial tests, the classifier computes the total number of spam words on the page. In some implementations, this includes computing the total number of spam words in the title, content, forward links, backlinks, and metadata of the page. The classifier then compares the number of spam words in each category to specified thresholds for each category. For example, the threshold for the number of spam words in a page that a backlink points from can be any suitable value, e.g. under 5 words, under 10 words, under 30 words, under 100 words, under 300 words, or under many more words, e.g., 1000 . . . . Generally, if all thresholds are met, the page can be identified as compromised. In some implementations, if some, but not all, of the thresholds are met, the page may not be identified as compromised and can be discarded. Individual thresholds may be increased or decreased to modify sensitivity of the classifier.
In some implementations, some exceptions may apply that may prevent the page from being identified as compromised 508 even though all thresholds are met. For example, the page may be a medical page that contains the names of drugs that are commonly classified as spam words. In another example, the page may be a page discussing various products that contains terms referencing those products that might, in some contexts, be considered spam words.
To avoid falsely classifying these pages as spam, the classifier performs additional comparisons to increase accuracy. The classifier computes a count of the most frequent words on the untainted and candidate compromised versions of the page. Then, the classifier compares these counts to compute a percentage of top words that appear in both the untainted and candidate compromised versions of the page. If the percentage exceeds a specified threshold, the page will not be identified as compromised. If the percentage does not satisfy a specified threshold, the page can be identified as compromised. In some implementations, the existence of spam words in the title of the page may be an exception, even if all thresholds are met. For example, if the percentage is below a specified threshold but spam words do not occur in the title, the page may not be identified as compromised. The specified threshold percentages can be any suitable value such as 5%, 10%, 25%, 35%, or 50%. In some implementations, if spam words occur in the title, the page can be identified as compromised.
In some implementations, an untainted page may have been previously identified as compromised. This may happen because the owner of the page submitted a reconsideration request, and the page was manually determined to be untainted. In this case, the classifier compares the page to the previous version of the page that was manually determined to be untainted. In some implementations, if a particular page reaches a threshold of search impressions and is determined to be compromised, the page is marked for manual review and not automatically determined to be compromised. For example, a search impression threshold can be 1,000, 10,000, 100,000, or 1,000,000 views. After a page is identified as compromised 508 , the page is added to a list of compromised URLs 512 . In some implementations, this list is stored in network storage. In some implementations, the list can be universally accessed by other data processing apparatus within the network. In some implementations, the system can send a notification to the owner of the page's site indicating the page has been identified as compromised.
FIG. 6 is a flow chart showing an example method 600 for identifying compromised search results. For convenience, the method 600 will be described with respect to a system having one or more computing devices that performs the method 600 . For example, the system can be a data processing apparatus that processes search queries.
The system receives a search query 602 . For example, the search query can be received from a user through a search interface provided by the system and displayed on a user device. For example, the user device can include a browser that presents a search field for inputting search queries.
The system obtains search results 604 responsive to the received search query. The search results identify resources responsive to the query and can include URLs corresponding to the respective resources. The system checks whether each search result exists in a list of compromised URLs 606 . The list of compromised URLs can include URLs determined to be compromised as described above with respect to FIGS. 2-5 . If none of the search results exist in the list of compromised URLs, the system provides the search results to the user for display 608 . The search results can be displayed as an ordered list of results. Each result can include a link to the corresponding resource as well as additional information about the resource. If a search result exists in the list of compromised URLs, the system can include a warning corresponding to the compromised search result when providing the search results 610 . In particular, the warning can be included with the corresponding search result for display. In some implementations, the warning reads “This page may have been compromised.”
FIG. 7 is a diagram showing an example search results page 700 including a warning displayed within search results. The search results page 700 can be presented on a client device, e.g., using a browser, based on search results provided by a search system. The search results can be provided in response to a submitted query. The search results page 700 includes search results 704 , 706 , 710 , and 712 . Search results Result 1 704 , Result 3 710 , and Result 4 712 are not identified as compromised. However, search result (Result 2 ) 706 has been identified as compromised, e.g., as described above with respect to FIGS. 1-6 . For the compromised result, the search results page 700 includes a warning 708 . In particular, the warning is presented with the compromised search result. For example, the warning reads “Warning: this page may have been compromised” and is presented immediately below the search result. In some other implementations, the warning can be presented in different forms, for example, using a different location relative to the compromised search result, different warning text, or with different visual effects, e.g., highlighting or other visual cues.
Embodiments of the subject matter and the operations described in this specification can be implemented in digital electronic circuitry, or in computer software, firmware, or hardware, including the structures disclosed in this specification and their structural equivalents, or in combinations of one or more of them. Embodiments of the subject matter described in this specification can be implemented as one or more computer programs, i.e., one or more modules of computer program instructions, encoded on computer storage medium for execution by, or to control the operation of, data processing apparatus. Alternatively or in addition, the program instructions can be encoded on an artificially generated propagated signal, e.g., a machine-generated electrical, optical, or electromagnetic signal, that is generated to encode information for transmission to suitable receiver apparatus for execution by a data processing apparatus. A computer storage medium can be, or be included in, a computer-readable storage device, a computer-readable storage substrate, a random or serial access memory array or device, or a combination of one or more of them. Moreover, while a computer storage medium is not a propagated signal, a computer storage medium can be a source or destination of computer program instructions encoded in an artificially generated propagated signal. The computer storage medium can also be, or be included in, one or more separate physical components or media (e.g., multiple CDs, disks, or other storage devices).
The operations described in this specification can be implemented as operations performed by a data processing apparatus on data stored on one or more computer-readable storage devices or received from other sources.
The term “data processing apparatus” encompasses all kinds of apparatus, devices, and machines for processing data, including by way of example a programmable processor, a computer, a system on a chip, or multiple ones, or combinations, of the foregoing The apparatus can include special purpose logic circuitry, e.g., an FPGA (field programmable gate array) or an ASIC (application specific integrated circuit). The apparatus can also include, in addition to hardware, code that creates an execution environment for the computer program in question, e.g., code that constitutes processor firmware, a protocol stack, a database management system, an operating system, a cross-platform runtime environment, a virtual machine, or a combination of one or more of them. The apparatus and execution environment can realize various different computing model infrastructures, such as web services, distributed computing and grid computing infrastructures.
A computer program (also known as a program, software, software application, script, or code) can be written in any form of programming language, including compiled or interpreted languages, declarative or procedural languages, and it can be deployed in any form, including as a stand alone program or as a module, component, subroutine, object, or other unit suitable for use in a computing environment. A computer program may, but need not, correspond to a file in a file system. A program can be stored in a portion of a file that holds other programs or data (e.g., one or more scripts stored in a markup language resource), in a single file dedicated to the program in question, or in multiple coordinated files (e.g., files that store one or more modules, sub programs, or portions of code). A computer program can be deployed to be executed on one computer or on multiple computers that are located at one site or distributed across multiple sites and interconnected by a communication network.
The processes and logic flows described in this specification can be performed by one or more programmable processors executing one or more computer programs to perform actions by operating on input data and generating output. The processes and logic flows can also be performed by, and apparatus can also be implemented as, special purpose logic circuitry, e.g., an FPGA (field programmable gate array) or an ASIC (application specific integrated circuit).
Processors suitable for the execution of a computer program include, by way of example, both general and special purpose microprocessors, and any one or more processors of any kind of digital computer. Generally, a processor will receive instructions and data from a read only memory or a random access memory or both. The essential elements of a computer are a processor for performing actions in accordance with instructions and one or more memory devices for storing instructions and data. Generally, a computer will also include, or be operatively coupled to receive data from or transfer data to, or both, one or more mass storage devices for storing data, e.g., magnetic, magneto optical disks, or optical disks. However, a computer need not have such devices. Moreover, a computer can be embedded in another device, e.g., a mobile telephone, a personal digital assistant (PDA), a mobile audio or video player, a game console, a Global Positioning System (GPS) receiver, or a portable storage device (e.g., a universal serial bus (USB) flash drive), to name just a few. Devices suitable for storing computer program instructions and data include all forms of non volatile memory, media and memory devices, including by way of example semiconductor memory devices, e.g., EPROM, EEPROM, and flash memory devices; magnetic disks, e.g., internal hard disks or removable disks; magneto optical disks; and CD ROM and DVD-ROM disks. The processor and the memory can be supplemented by, or incorporated in, special purpose logic circuitry.
To provide for interaction with a user, embodiments of the subject matter described in this specification can be implemented on a computer having a display device, e.g., a CRT (cathode ray tube) or LCD (liquid crystal display) monitor, for displaying information to the user and a keyboard and a pointing device, e.g., a mouse or a trackball, by which the user can provide input to the computer. Other kinds of devices can be used to provide for interaction with a user as well; for example, feedback provided to the user can be any form of sensory feedback, e.g., visual feedback, auditory feedback, or tactile feedback; and input from the user can be received in any form, including acoustic, speech, or tactile input. In addition, a computer can interact with a user by sending resources to and receiving resources from a device that is used by the user; for example, by sending web pages to a web browser on a user's client device in response to requests received from the web browser.
Embodiments of the subject matter described in this specification can be implemented in a computing system that includes a back end component, e.g., as a data server, or that includes a middleware component, e.g., an application server, or that includes a front end component, e.g., a client computer having a graphical user interface or a Web browser through which a user can interact with an implementation of the subject matter described in this specification, or any combination of one or more such back end, middleware, or front end components. The components of the system can be interconnected by any form or medium of digital data communication, e.g., a communication network. Examples of communication networks include a local area network (“LAN”) and a wide area network (“WAN”), an inter-network (e.g., the Internet), and peer-to-peer networks (e.g., ad hoc peer-to-peer networks).
The computing system can include clients and servers. A client and server are generally remote from each other and typically interact through a communication network. The relationship of client and server arises by virtue of computer programs running on the respective computers and having a client-server relationship to each other. In some embodiments, a server transmits data (e.g., an HTML page) to a client device (e.g., for purposes of displaying data to and receiving user input from a user interacting with the client device). Data generated at the client device (e.g., a result of the user interaction) can be received from the client device at the server.
A system of one or more computers can be configured to perform particular operations or actions by virtue of having software, firmware, hardware, or a combination of them installed on the system that in operation causes or cause the system to perform the actions. One or more computer programs can be configured to perform particular operations or actions by virtue of including instructions that, when executed by data processing apparatus, cause the apparatus to perform the actions.
While this specification contains many specific implementation details, these should not be construed as limitations on the scope of any inventions or of what may be claimed, but rather as descriptions of features specific to particular embodiments of particular inventions. Certain features that are described in this specification in the context of separate embodiments can also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple embodiments separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination.
Similarly, while operations are depicted in the drawings in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results. In certain circumstances, multitasking and parallel processing may be advantageous. Moreover, the separation of various system components in the embodiments described above should not be understood as requiring such separation in all embodiments, and it should be understood that the described program components and systems can generally be integrated together in a single software product or packaged into multiple software products.
Thus, particular embodiments of the subject matter have been described. Other embodiments are within the scope of the following claims. In some cases, the actions recited in the claims can be performed in a different order and still achieve desirable results. In addition, the processes depicted in the accompanying figures do not necessarily require the particular order shown, or sequential order, to achieve desirable results. In certain implementations, multitasking and parallel processing may be advantageous.
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Methods, systems, and apparatus, including computer programs encoded on a computer storage medium, for detecting compromised resources. In one aspect, a method includes receiving a resource; determining the resource is tainted based on one or more indications that the resource has been compromised; merging the tainted resource with previous versions of the resource that were tainted to generate a most recent tainted resource; determining the tainted resource is compromised by analyzing attributes of the most recent tainted resource that satisfy one or more threshold criteria that indicate the resource has been compromised; and identifying the tainted resource as compromised.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an objective lens for optical apparatuses, and in particular, to an infinity-corrected objective lens which is suitable for a microscope using wave-lengths of approximately 250 nm in a deep-ultraviolet region and has a high numerical aperture and a high magnification.
2. Description of Related Art
It is known that objective lenses for microscopes using wavelengths of approximately 250 nm in a deep-ultraviolet region are roughly divided into three types. The first type lens, as disclosed in each of Japanese Patent Preliminary Publication Nos. Hei 6-242381 and Hei 10-104510, is constructed with only a plurality of lenses made of the same medium (quartz in most cases) and cannot be in principle corrected for chromatic aberration. The second type lens, as disclosed in each of Japanese Patent Preliminary Publication Nos. Hei 5-72482, Hei 9-243923, and Hei 11-249025, is designed so that lenses made of different media (quartz and fluorite in most cases) are cemented with adhesives, and thereby chromatic aberration can be corrected. The third type lens, recently disclosed in Japenese Patent Preliminary Publication No. Hei 11-167067, is such that lenses made of quartz and fluorite are used to correct chromatic aberration, but they are not cemented with adhesives.
However, the first type lens, which cannot be in principle corrected for chromatic aberration, has the problem that when a light source with a wavelength width (such as a lamp or an excimer laser in which wavelengths are not in a narrow band) is used, light-collecting performance is considerably degraded due to chromatic aberration and thus predetermined resolution governed by the wavelength and the numerical aperture (NA) of the objective lens is not obtained. The second type lens, in which chromatic aberration can be corrected, has no such a problem. However, it has the problem that an adhesive for favorably transmitting deep-ultraviolet light is not virtually available, and even if it is available, difficulties about cementing force and workability are raised. It is common practice to render light, for example, from a lamp, incident on an objective lens, but if light with high energy, for example, from a laser, is rendered incident thereon, this causes the problem that the adhesive is deteriorated by the deep-ultraviolet light and the transmittance of the objective lens is reduced.
The third type lens is designed to solve all the problems encountered by the first and second type lenses. However, the lens discussed in Hei 11-167067 is basically related to an objective lens for laser repair using a deep-ultraviolet laser, and its embodiment discloses only an objective lens with a numerical aperture of 0.4. With this construction, the problem arises that it is quite impossible to reduce the wavelength so that high resolution can be obtained. Specifically, the resolution of a microscope is basically governed by the wavelength and the numerical aperture of the objective lens, but the central wavelength of visible light used in an ordinary microscope is nearly 550 nm and a dry objective lens has a maximum numerical aperture of about 0.9. Thus, if a wavelength used is set at approximately 250 nm, the wavelength is about halved and hence the resolution is approximately doubled. In this case, however, the numerical aperture is the same. In the objective lens with a numerical aperture of 0.4, even though the wavelength used is set at approximately 250 nm, the wavelength is about halved and the numerical aperture is also about halved. Thus, they are offset, and the result is that the resolution is exactly the same as in a conventional microscope.
SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to provide an objective lens which is favorably used in an optical apparatus employing wavelengths in deep-ultraviolet region and has a high numerical aperture so that chromatic aberration can be corrected by only combining single lenses of different media without using any cemented lens and resolution is dramatically improved to meet a fine design involved in a high density of a semiconductor and a large volume of an optical recording medium.
In order to achieve this object, the objective lens of the present invention includes a first lens unit constructed with a plurality of single lenses, having a negative power as a whole, and a second lens unit constructed with a plurality of single lenses, arranged on the object side of the first lens unit. Each of the first and second lens units is provided with air spaces between positive and negative lenses of different media and has at least one pair of lenses designed to satisfy all the following conditions when the parfocal distance of the objective lens is denoted by L (mm), an air apace by d (mm), the radius of curvature of a lens surface with a positive power opposite to the air space by Rp, and the radius of curvature of a lens surface with a negative power opposite to the air space by Rn, and in addition to the pair of lenses, the second lens unit has at least one single positive biconvex lens and at least one single positive meniscus lens, and thereby it becomes possible to correct chromatic aberration and to favorably obtain resolution corresponding to a high numerical aperture and a wavelength used:
0.01 <d (1)
d/L< 0.01 (2)
0.88 <Rp/Rn< 1.14 (3)
In the objective lens mentioned above, the second lens unit has at least three pairs of lenses and is designed to satisfy the following condition, in addition to Conditions (1), (2), and (3), when the Abbe's number of each of positive lenses contained in these pairs of lenses is represented by ν dp and the Abbe's number of each of negative lenses contained in the pairs of lenses is represented by ν dn, and thereby the three pairs of lenses become equivalent to at least three cemented lenses so that aberrations including chromatic aberration can be favorably corrected:
ν dp>ν dn (4)
Further, in the objective lens mentioned above, when the second lens unit is designed to have at least one lens configuration in which three adjacent lenses make two pairs of lenses, at least one false pair of lenses corresponding to a cemented triplet is obtained, and it becomes possible to correct chromatic aberration more favorably.
This and other objects as well as features and advantages of the present invention will become apparent from the following detailed description of the preferred embodiments when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view showing a lens arrangement of a first embodiment in the objective lens of the present invention;
FIGS. 2A, 2 B, and 2 C are diagrams showing aberration characteristics of the first embodiment;
FIG. 3 is a view showing a lens arrangement of a second embodiment in the objective lens of the present invention;
FIGS. 4A, 4 B, and 4 C are diagrams showing aberration characteristics of the second embodiment;
FIG. 5 is a view showing a lens arrangement of a third embodiment in the objective lens of the present invention;
FIGS. 6A, 6 B, and 6 C are diagrams showing aberration characteristics of the third embodiment;
FIG. 7 is a view showing a lens arrangement of a fourth embodiment in the objective lens of the present invention; and
FIGS. 8A, 8 B, and 8 C are diagrams showing aberration characteristics of the fourth embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The objective lens of the present invention, as mentioned above, is constructed with single lenses, without cementing lenses of different media with adhesives. According to the present invention, not only can chromatic aberration be corrected, but also the above problem produced in the case where the adhesive is used can be completely solved. Furthermore, for example, resolution fitted for wavelengths of approximately 250 nm in the deep-ultraviolet region and a high numerical aperture can be obtained, and thus the present invention is entirely favorable for an objective lens used in an optical apparatus such as an ultraviolet microscope.
However, if the objective lens fails to satisfy Condition (1) so that an air space between a pair of lenses is below 0.01, a lens space becomes extremely narrow and adjacent lenses will be nearly in contact. It is practically difficult to fabricate such a lens system. Condition (2) defines a condition for bringing lenses close to each other. If the value of this condition exceeds the upper limit of 0.01, the air space between the lenses becomes extremely wide and chromatic aberration cannot be favorably corrected. Condition (3) specifies a condition for nearly equalizing radii of curvature of opposite surfaces of a pair of lenses, and when the objective lens satisfies this condition, aberrations including chromatic aberration can be favorably corrected. However, if the limit of the condition is passed, correction for chromatic aberration becomes particularly difficult. From this, it may be said that Conditions (2) and (3) are conditions for allowing spherical aberration and chromatic aberration to be corrected by false behavior of lenses as in the case of a cemented lens even though an adhesive is not used.
Also, in Condition (2), the symbol L is defined as the parfocal distance of the objective lens. However, where the parfocal distance of the objective lens is nearly equal to the overall length of the objective lens, the overall length of the objective lens may be used as L. Here, the overall length of the objective lens refers to a distance from the first lens surface to the last lens surface.
In the present invention, the second lens unit may be designed to include at least three pairs of lenses. In this case, when the Abbe's number ν dp of the positive lens and the Abbe'number ν dn of the negative lens of each pair of lenses are set to satisfy the condition of ν dp>ν dn (Condition (4)), the three pairs of lenses become equivalent to at least three cemented lenses, and aberrations including chromatic aberration can be corrected more favorably. Condition (4) is related to the Abbe's numbers of the pair of lenses. Briefly described here is the reason why the relation between the Abbe's numbers of the positive and negative lenses is established as in Condition (4). In the present invention, the first lens unit and the second lens unit are different in behavior, so that in the first lens unit, monochromatic aberration is chiefly corrected, while in the second lens unit, axial chromatic aberration is principally corrected. Thus, in the second lens unit, by using a medium with low dispersion of a large Abbe's number for the positive lens and a medium with high dispersion of a small Abbe's number for the negative lens, chromatic aberration is effectively corrected. It the objective lens fails to satisfy Condition (4), axial chromatic aberration will be considerably produced and the chromatic aberration cannot be corrected as a whole.
In the present invention, the second lens unit may also be designed to include at least one lens configuration in which three lenses are brought close to one another. The three lenses in this case are arranged in the order of positive, negative, and positive lenses or negative, positive, and negative lenses. In this arrangement, two pairs of lenses are present and thus it may be said that chromatic aberration is corrected in each pair of lenses. However, from another viewpoint, the three lenses close to one another can be thought of as a cemented triplet. In this case, at least one pair of lenses corresponding to the cemented triplet will be provided, and chromatic aberration can be corrected as in the cemented triplet. In an ordinary objective lens, when the numerical aperture is relatively small, chromatic aberration can be corrected by using a cemented doublet. However, in an objective lens with a numerical aperture of 0.7 or more, notably of the order of 0.9, it becomes difficult to correct chromatic aberration with only the cemented doublet. Thus, even when the objective lens does not include any cemented lens as in the present invention, chromatic aberration can be favorably corrected by using a false cemented triplet such as that described above. In the present invention, the objective lens may be constructed so that the first lens unit has at least one lens with a positive power and at least one lens with a negative power, and the second lens unit has at least five biconvex lenses with positive powers and at least two meniscus lenses with positive powers. In doing so, monochromatic aberration can be favorably corrected in the main. In the objective lens with a numerical aperture of 0.7 or more, notably of the order of 0.9, even monochromatic aberration cannot be corrected unless the angle of a ray of light emanating from an object is reduced. However, when two meniscus lenses are used to gradually reduce the angle of the ray of light, correction for the aberration becomes possible. In the first lens unit in which a light beam is narrowed to some extent, it is required that a concave surface with a strong power is placed to restore a ray of light to parallel light and correct curvature of field and coma. In this case, if only a lens with a negative power is simply placed, the balance between aberrations will be lost. However, when at least one lens with a positive power and at least one lens with a negative power are placed, aberrations including chromatic aberration can be corrected, holding a good balance as a whole. The objective lens of the present invention can be constructed with lenses made of quartz and fluorite. In such a construction, an objective lens which is good in workability ability and durability and has a high transmittance can be obtained, as an objective lens for wavelengths of approximately 250 nm in a deep-ultraviolet region, even though media with deliquescence and birefringence are not used.
Four embodiments of the present invention will be explained below with reference to FIGS. 1-8C. Each of these embodiments cites an objective lens which has a focal length of 1.8 mm, a numerical aperture of 0.9 (0.95 in the second embodiment), a working distance of 0.3 mm (0.2 mm in the second embodiment), a parfocal length of 45 mm, and a compensating wavelength region of 248±1 nm. When this objective lens is combined with an imaging lens with a focal length of 180 mm, the values of a field number of 6 mm and a magnification of 100× are obtained. Since chromatic aberration is corrected within a limit of 248±1 nm, the objective lens can be used in combination with a KrF excimer laser in which wavelengths are not in a narrow band, and has sufficient durability in respect to a laser with high energy because the adhesive is not used. Furthermore, the objective lens is combined with a band-pass filter which has a half-width of about 2 nm, a specimen can be illuminated by a mercury lamp and observed at a stage before laser irradiation.
FIGS. 1, 3 , 5 , and 7 show lens arrangements of the embodiments in the present invention. In each of these figures, the right side indicates the object side, and individual lenses are represented by the reference symbols of L 1 -L 8 in this order from the opposite side of the object side. Reference symbols G 1 and G 2 designate the first lens unit and the second lens unit, respectively, and P 1 -P 7 designate pairs of lenses defined by the present invention. FIGS. 2A-2C, 4 A- 4 C, 6 A- 6 C, and 8 A- 8 C show aberration characteristics of the embodiments, including spherical aberration, curvature of field, and distortion from the left side of the figure in each of the embodiments. Each of these aberrations is produced at the surface of the object where a ray is reversely traced through the objective lens and is expressed in millimeters or percentages. Spherical aberration is specified with respect to wavelengths of 248 nm indicated by a dotted line, 247 nm by a chain line, and 249 nm by a solid line.
First Embodiment
The lens arrangement of the first embodiment is shown in FIG. 1, and aberration characteristics are shown in FIGS. 2A-2C. As seen from FIG. 1, the first lens unit G 1 of this embodiment is constructed with four lenses L 1 -L 4 and includes two pairs of lenses P 1 and P 2 . The second lens unit G 2 is constructed with twelve lenses L 5 -L 16 and includes five pairs of lenses P 3 -P 7 so that three adjacent lenses L 5 -L 7 make two pairs of lenses P 3 and P 4 to construct a false cemented triplet. Each of the pairs of lenses P 3 -P 7 of the second lens unit G 2 includes a lens with a negative power made of quartz (an Abbe's number of 68) and a lens with a positive power made of fluorite (an Abbe's of 95), and thus satisfies Condition (4). From Data 1 shown below, it is obvious that each of the pairs of lenses P 1 -P 7 also satisfies Conditions (1)-(3). Numerical values used in Data 1 are expressed in millimeters, RDY represents the radius of curvature of each lens surface, and THI represents an air space along the optical axis between or the thickness of each lens. The same is said of Data 2, 3, and 4 described
Data 1
Surface
Condition
Condition
No.
RDY
THI
Medium
(2)
(3)
1
INFINITY
−2.00
2
2.301
1.84
SiO 2
L1
3
1.690
1.10
4
−1.961
4.00
CaF 2
L2
P1
1.072
5
−2.317
0.15
0.0034
6
−2.161
4.00
SiO 2
L3
P2
0.894
7
7.967
0.14
0.0031
8
8.910
3.07
CaF 2
L4
9
−11.971
0.10
10
6.986
4.40
CaF 2
L5
P3
1.059
11
−7.440
0.15
0.0032
12
−7.027
1.00
SiO 2
L6
P4
1.054
13
6.417
0.10
0.0022
14
6.088
4.38
CaF 2
L7
P5
1.112
15
−6.966
0.23
0.0051
16
−6.263
1.00
SiO 2
L8
17
7.632
0.74
18
17.025
2.87
CaF 2
L9
19
−9.501
0.10
20
8.406
3.50
CaF 2
L10
P6
1.061
21
−8.440
0.13
0.0028
22
−7.956
1.00
SiO 2
L11
23
−47.024
0.78
24
−8.228
1.29
SiO 2
L12
P7
0.883
25
5.778
0.24
0.0052
26
6.542
3.49
CaF 2
L13
27
−7.677
0.10
28
7.584
1.92
CaF 2
L14
29
13.739
0.12
30
4.947
2.31
CaF 2
L15
31
14.800
0.10
32
2.196
2.32
SiO 2
L16
33
17.211
0.36
34
INFINITY
Second Embodiment
The lens arrangement of the second embodiment is shown in FIG. 3, and aberration characteristics are shown in FIGS. 4A-4C. As seen from FIG. 3, the first lens unit G 1 of this embodiment is also constructed with four lenses L 1 -L 4 and includes two pairs of lenses P 1 and P 2 . The second lens unit G 2 is constructed with thirteen lenses L 5 -L 17 and includes five pairs of lenses P 3 -P 7 . In the second embodiment, the second lens unit G 2 has two false cemented triplets, one in which three lenses L 5 -L 7 make two pairs of lenses P 3 and P 4 and the other in which three lenses L 10 -L 12 make two pairs of lenses P 5 and P 6 . Each of the pairs of lenses P 3 -P 7 of the second lens unit G 2 includes a lens with a negative power made of quartz (an Abbe's number of 68) and a lens with a positive power made of fluorite (an Abbe's number of 95), and thus satisfies Condition (4). From Data 2 shown below, it is obvious that each of the pairs of lenses P 1 -P 7 also satisfies Conditions (1)-(3).
Data 2
Surface
Condition
Condition
No.
RDY
THI
Medium
(2)
(3)
1
INFINITY
−2.00
2
2.770
2.66
SiO 2
L1
3
1.629
0.83
4
−2.356
3.86
CaF 2
L2
P1
1.102
5
−2.468
0.22
0.0050
6
−2.239
3.43
SiO 2
L3
P2
0.902
7
8.035
0.13
0.0028
8
8.913
2.71
CaF 2
L4
9
−9.537
0.10
10
7.113
4.06
CaF 2
L5
P3
1.046
11
−7.107
0.13
0.0029
12
−6.794
1.00
SiO 2
L6
P4
1.081
13
6.496
0.10
0.0022
14
6.009
4.18
CaF 2
L7
15
−7.173
0.24
16
−6.373
1.00
SiO 2
L8
17
7.655
0.78
18
20.340
2.63
CaF 2
L9
19
−10.529
0.10
20
17.247
1.00
SiO 2
L10
P5
1.028
21
6.454
0.16
0.0035
22
6.278
4.28
CaF 2
L11
P6
1.111
23
−7.383
0.23
0.0050
24
−6.647
1.00
SiO 2
L12
25
42.369
0.10
26
15.694
1.00
SiO 2
L13
P7
0.887
27
5.630
0.28
0.0062
28
6.346
3.68
CaF 2
L14
29
−9.541
0.10
30
7.431
1.99
CaF 2
L15
31
14.337
0.10
32
4.637
2.15
CaF 2
L16
33
8.464
0.10
34
2.121
2.40
SiO 2
L17
35
17.791
0.27
36
INFINITY
Third Embodiment
The lens arrangement of the third embodiment is shown in FIG. 5, and aberration characteristics are shown in FIGS. 6A-6C. As seen from FIG. 5, the first lens unit G 1 of this embodiment is constructed with five lenses L 1 -L 5 and includes two pairs of lenses P 1 and P 2 . The second lens unit G 2 is constructed with thirteen lenses L 6 -L 18 and includes five pairs of lenses P 3 -P 7 . In the third embodiment, the second lens unit G 2 has two false cemented triplets, one in which three lenses L 6 -L 8 make two pairs of lenses P 3 and P 4 and the other in which three lenses L 1 -L 13 make two pairs of lenses P 5 and P 6 . Each of the pairs of lenses P 3 -P 7 of the second lens unit G 2 includes a lens with a negative power made of quartz (an Abbe's number of 68) and a lens with a positive power made of fluorite (an Abbe's number of 95), and thus satisfies Condition (4). From Data 3 shown below, it is obvious that each of the pairs of lenses P 1 -P 7 also satisfies Conditions (1)-(3).
Data 3
Surface
Condition
Condition
No.
RDY
THI
Medium
(2)
(3)
1
INFINITY
−2.00
2
2.759
2.71
SiO 2
L1
3
1.589
0.77
4
−2.394
1.00
CaF 2
L2
P1
0.900
5
9.405
0.10
0.0023
6
10.449
2.64
SiO 2
L3
7
−3.158
0.28
8
−2.461
4.00
SiO 2
L4
P2
0.907
9
8.164
0.13
0.0028
10
9.001
2.75
CaF 2
L5
11
−9.396
0.10
12
7.150
4.21
CaF 2
L6
P3
1.052
13
−6.905
0.13
0.0032
14
−6.565
1.00
SiO 2
L7
P4
1.087
15
6.486
0.10
0.0022
16
5.969
4.23
CaF 2
L8
17
−7.004
0.24
18
−6.222
1.00
SiO 2
L9
19
7.878
0.59
20
14.805
2.75
CaF 2
L10
21
−10.249
0.10
22
26.379
1.00
SiO 2
L11
P5
1.032
23
6.142
0.10
0.0022
24
5.951
4.08
CaF 2
L12
P6
1.101
25
−6.965
0.20
0.0045
26
−6.326
1.00
SiO 2
L13
27
1827.930
0.10
28
24.702
1.00
SiO 2
L14
P7
0.892
29
5.203
0.25
0.0057
30
5.834
3.36
CaF 2
L15
31
−10.631
0.10
32
6.836
1.97
CaF 2
L16
33
13.351
0.10
34
4.310
2.11
CaF 2
L17
35
7.294
0.10
36
2.177
2.32
SiO 2
L18
37
18.560
0.36
38
INFINITY
Fourth Embodiment
The lens arrangement of the fourth embodiment is shown in FIG. 7, and aberration characteristics are shown in FIGS. 8A-8C. As seen from FIG. 7, the first lens unit G 1 of this embodiment is constructed with five lenses L 1 -L 5 and includes one pair of lenses P 1 . The second lens unit G 2 is constructed with thirteen lenses L 6 -L 18 and includes six pairs of lenses P 2 -P 7 so that five adjacent lenses L 6 -L 10 make four pairs of lenses P 2 -P 5 to construct false cemented triplets. Each of the pairs of lenses P 2 -P 7 of the second lens unit G 2 includes a lens with a negative power made of quartz (an Abbe's number of 68) and a lens with a positive power made of fluorite (an Abbe's number of 95), and thus satisfies Condition (4). From Data 4 shown below, it is obvious that each of the pairs of lenses P 1 -P 7 also satisfies Conditions (1)-(3).
Data 4
Surface
Condition
Condition
No.
RDY
THI
Medium
(2)
(3)
1
INFINITY
−3.00
2
2.420
1.54
SiO 2
L1
3
3.508
2.30
4
−1.737
1.00
SiO 2
L2
5
6.392
4.86
6
−12.159
2.95
SiO 2
L3
7
−3.813
0.47
8
−2.801
2.07
SiO 2
L4
P1
0.905
9
10.872
0.13
0.0028
10
12.018
2.60
CaF 2
L5
11
−7.384
0.10
12
7.985
3.77
CaF 2
L6
P2
1.092
13
−7.801
0.21
0.0048
14
−7.144
1.00
SiO 2
L7
P3
1.116
15
7.808
0.10
0.0022
16
6.993
4.60
CaF 2
L8
P4
1.083
17
−7.658
0.20
0.0045
18
−7.072
1.00
SiO 2
L9
P5
0.978
19
7.442
0.10
0.0023
20
7.609
3.46
CaF 2
L10
21
−10.351
0.10
22
86.624
1.00
SiO 2
L11
P6
0.984
23
5.399
0.10
0.0022
24
5.485
3.68
CaF 2
L12
P7
1.086
25
−7.392
0.16
0.0036
26
−6.807
1.00
SiO 2
L13
27
−33.377
0.10
28
11.127
1.00
SiO 2
L14
29
3.838
0.40
30
4.601
2.15
CaF 2
L15
31
INFINITY
0.10
32
7.016
1.20
SiO 2
L16
33
8.681
0.10
34
4.266
1.99
CaF 2
L17
35
INFINITY
0.10
36
1.790
1.94
SiO 2
L18
37
6.024
0.40
38
INFINITY
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An objective lens includes a first lens unit constructed with a plurality of single lenses, having a negative power as a whole, and a second lens unit constructed with a plurality of single lenses, arranged on the object side of the first lens unit. Each of the first and second lens units is provided with air spaces between positive and negative lenses of different media and has at least one pair of lenses designed to satisfy all the following conditions when the parfocal distance of the objective lens is denoted by L (mm), an air apace by d (mm), the radius of curvature of a lens surface with a positive power opposite to the air space by Rp, and the radius of curvature of a lens surface with a negative power opposite to the air space by Rn, and in addition to the pair of lenses, the second lens unit has at least one single positive biconvex lens and at least one single positive meniscus lens, and thereby it becomes possible to correct chromatic aberration and to favorably obtain resolution corresponding to a high numerical aperture and a wavelength used:
0.01<d
d/L<0.01
0.88<Rp/Rn<1.14.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] Embodiments described herein generally relate to a thrust chamber for use in a wellbore. More particularly, embodiments described herein relate to a thrust chamber having a flow path configured to circulate lubricating fluids in a motor seal and stabilize a thrust runner.
[0003] 2. Description of the Related Art
[0004] To obtain hydrocarbon fluids from an earth formation, a wellbore is drilled into the earth to intersect an area of interest within a formation. The wellbore may then be “completed” by inserting casing within the wellbore and setting the casing therein using cement. In the alternative, the wellbore may remain uncased (an “open hole wellbore”), or may become only partially cased. Regardless of the form of the wellbore, production tubing is typically run into the wellbore primarily to convey production fluid (e.g., hydrocarbon fluid, which may also include water) from the area of interest within the wellbore to the surface of the wellbore.
[0005] Often, pressure within the wellbore is insufficient to cause the production fluid to naturally rise through the production tubing to the surface of the wellbore. Thus, to carry the production fluid from the area of interest within the wellbore to the surface of the wellbore, artificial-lift means is sometimes necessary. The most prominent artificial-lift means are the use of down hole pumps and gas lift.
[0006] Some artificially-lifted wells are equipped with electric submersible pumps. These pumps include electric motors which are submersible in the wellbore fluids. The electric motor connects to a motor seal which connects to a pump. The motor seal functions to seal the motor from the wellbore fluids while allowing the motor to transfer torque to the pump. A motor seal typically includes a thrust protection portion. A thrust protection portion prevents downward thrust and forces created by the pump from damaging the motor. Further, a thrust protection portion prevents up-thrust created by the motor during start-up from damaging the pump or motor seal.
[0007] A thrust protection portion typically includes: a housing for containing two bearing portions, a thrust block, and a lubricating fluid. The thrust block is typically located between each of the bearing portions. The thrust block absorbs the downward forces created by the pump and the upward forces created by the motor during operation of the pump. The bearing portions prevent the thrust block from moving axially relative to the pump assembly while resisting the upward and downward forces.
[0008] The lubricating fluid in the housing is a fixed amount of fluid that circulates in the housing. The lubricating fluid lubricates the thrust block during operation of the pump assembly. During operation, the lubricating fluid absorbs energy from the thrust block and bearing portions, which causes the lubricating fluid to heat up and lose its ability to lubricate over the life of the pumping assembly.
[0009] Circulation of the lubricating fluid occurs in a large gap between the thrust block and the housing. This circulation creates turbulence near the bearing portions. The turbulence creates uneven load patterns on the bearing portion and thrust block. The uneven load patterns results in enhanced wear and vibration of the bearing portion and the thrust blocks.
[0010] Therefore, a need exists for a thrust chamber with the ability to circulate fluids into and/or out of the chamber. There is a further need for a thrust chamber configured to reduce unbalanced forces while circulating fluids.
SUMMARY OF THE INVENTION
[0011] The embodiments described herein relate to an apparatus for sealing and protecting a motor for use in a wellbore. The apparatus includes a housing, a thrust runner and a radial bearing. The thrust runner is configured configured to fit inside the substantially cylindrical housing. The radial bearing is located between the thrust runner and the housing. A flow path is created past the thrust runner by one or more grooves between the housing and the thrust runner, wherein the one or more grooves allow a fluid to flow past the radial bearing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
[0013] FIG. 1 is a schematic view of a wellbore according to one embodiment described herein.
[0014] FIG. 2 is a cross-sectional view of a motor seal according to one embodiment described herein.
[0015] FIG. 3 is a cross-sectional view of a thrust chamber according to one embodiment described herein.
[0016] FIGS. 4A and 4B are a cross-sectional view of a thrust housing according to one embodiment described herein.
[0017] FIG. 5A is a top view of a thrust runner according to one embodiment described herein.
[0018] FIG. 5B is a cross-sectional view of a thrust runner according to one embodiment described herein.
[0019] FIG. 6A is a perspective view of a bearing portion according to one embodiment described herein.
[0020] FIG. 6B is a side view of a bearing portion according to one embodiment described herein.
[0021] FIG. 6C is a top view of a bearing portion according to one embodiment described herein.
DETAILED DESCRIPTION
[0022] FIG. 1 is a schematic view of a wellbore 100 according to one embodiment described herein. The wellbore 100 includes a tubular 102 which is secured in the wellbore 100 using cement, not shown. The wellbore 100 and the tubular 102 intersects at least one production zone 104 . The tubular 102 is typically a string of casing and/or liner; however, it could be any tubular used in downhole operations. Further, the wellbore 100 may be an open hole wellbore. As shown, a conveyance 106 is within the tubular 102 and coupled to an artificial lift assembly 108 . As shown, the conveyance is production tubing; however, it should be appreciated that the conveyance could be any conveyance for delivering the artificial lift assembly 108 into the wellbore 100 for example: a wire line, a slick line, a coiled tubing, a co-rod, a drill string, a casing, etc. The artificial lift assembly 108 pushes the production fluids from the wellbore to the surface of the wellbore 100 .
[0023] The artificial lift assembly 108 includes: a motor 110 , a motor seal 112 , an intake 114 , and a pump 116 . The motor 110 , as shown, is an electric motor; however, it is contemplated that any motor for use in a wellbore may be used. The motor seal 112 includes a thrust chamber which includes one or more flow paths adapted to circulate a lubricating fluid, not shown, from a seal portion of the motor seal to the thrust chamber, and optionally into the motor 110 . The motor seal 112 prevents thrust loads from affecting the motor 110 and/or the pump 116 while allowing torque to transfer from the motor 1 10 to the pump 1 16 . The motor seal 112 equalizes the pressure in the artificial lift assembly 108 with the wellbore fluids and lubricates the thrust chamber as will be discussed in more detail below. The pump 116 is a multistage centrifugal pump; however, it is contemplated that any downhole pump may be used. The intake 114 provides a flow path from the wellbore to the interior of the artificial lift assembly 108 . The intake 114 may be any intake used in downhole operations. It is contemplated that the parts of the artificial lift assembly 108 be arranged in any order so long as the wellbore fluids are pushed to the surface by the pump 116 .
[0024] FIG. 2 shows a cross-sectional view of the motor seal 112 of the artificial lift assembly 108 according to one embodiment of the present invention. The motor seal 112 includes three seal portions 200 , 202 , and 204 in series coupled to the thrust chamber 206 . Although shown as having three seal portions 200 , any number of seal portions may be used including one. A shaft 208 runs through the seal portions 200 , 202 , and 204 and the thrust chamber 206 . The motor seal 112 includes a first connector end 210 and a second connector end 212 . As shown the first connector end 210 couples to the motor 110 , and the second connector end 212 couples to the intake 114 and/or the pump 116 , as shown in FIG. 1 . The motor 110 includes a motor drive shaft, not shown, which couples to the shaft 208 near the first connector end 210 of the motor seal 112 . The pump 116 includes a pump drive shaft, not shown, which couples to the shaft 208 near the second connector end 212 of the motor seal 112 . The connection between at least one of the motor shaft or the pump shaft and the shaft 208 may include an axial slip, not shown, which allows the shaft 208 to move at least partially in the axial direction, such as a splined connection while the motor 110 transfers torque to the shaft 208 . The shaft 208 transfers torque from the motor shaft to the pump shaft. The pump shaft operates the pump in order to push the wellbore fluids to the surface of the wellbore 100 .
[0025] The seal portions 200 , 202 , and 204 , as shown, are a labyrinth type motor seal. Each of the seal portions 200 , 202 , and 204 include a chamber 214 , a mechanical seal 216 and a series of ports 218 . The series of ports 218 are in fluid communication with the thrust chamber 206 , as will be discussed in more detail below. Prior to being placed in the wellbore, the motor seal 112 is filled with a lubricating fluid, not shown. The lubricating fluid, in one embodiment, is a dielectric fluid having a specific gravity lower than typical wellbore fluids. Further, any lubricating fluid may be used.
[0026] The thrust chamber 206 includes a thrust housing 219 , a thrust runner 220 , an up-thrust bearing 222 , and a down thrust bearing 224 . The thrust runner 220 couples to the shaft 208 in a manner that allows it to rotate with the shaft 208 , while preventing relative axial movement between the shaft 208 and the thrust runner 220 . The up-thrust bearing 222 and a down thrust bearing 224 are fixed relative to the thrust housing 219 . The up-thrust bearing 222 and the down thrust bearing 224 prevent axial force in the shaft 208 from transferring to the motor 110 or the pump 116 during operation. Between the thrust housing 219 and the thrust runner 220 is a radial bearing 226 . The radial bearing 226 is a fluid bearing which prevents the thrust runner 220 from contacting the thrust housing 219 during operation. The fluid bearing consists of the lubricating fluid which is a relatively non-compressible fluid and is located in a relatively small radial clearance between the thrust housing 219 and the thrust runner 220 in one embodiment. The thrust housing 219 and/or the thrust runner 220 include a flow path through the radial bearing 226 , as will be discussed in more detail below.
[0027] FIG. 3 shows a cross-sectional view of the thrust chamber 206 and the seal portion 204 . The mechanical seal 216 is a typical mechanical seal used in a motor seal. The thrust housing 219 , as shown, couples to the first connector end 210 and the seal portion 204 . Seal rings 300 prevent fluid from leaking into or out of the thrust chamber 206 from the wellbore 100 . The thrust runner 220 couples to the shaft 208 via couplings 302 . The couplings 302 prevent relative axial movement between the thrust runner 220 and the shaft 208 . The upper thrust bearing 222 has one or more load pads 304 and a coupling 306 for coupling the up-thrust bearing 222 to the thrust housing 219 . The coupling 306 prevents the upper thrust bearing 222 from moving in a substantially axial or rotational direction during operation. The downward thrust bearing 224 may be substantially the same as the upper thrust bearing 222 ; therefore, only details of the upper thrust bearing 222 will be discussed in detail. The coupling 306 may be accomplished in any manner for example by bolts, screws, welding, etc.
[0028] FIGS. 4A and 4B show cross-sectional views of the thrust housing 219 , according to one embodiment of the present invention. The thrust housing 219 includes two or more housing grooves 400 in an inner surface 402 of the housing. The housing grooves 400 may be a portion of the flow path which will be described in more detail below. Two grooves 400 are shown; however, any number of grooves may be provided so long as the grooves 400 are symmetrical around inner surface 402 of the thrust housing 219 .
[0029] FIGS. 5A and 5B show a top and cross-sectional side view of the thrust runner 220 , respectively. As shown, the thrust runner 220 includes two or more grooves 500 on an outer surface 502 of the thrust runner 220 . In one embodiment, the grooves 500 may be used in conjunction with the housing grooves 400 to form a part of the flow path. Three grooves 500 are shown; however, it should be appreciated that any number of grooves may be provided so long as the grooves 500 are substantially symmetrical around outer surface 502 of the thrust runner 220 . At least one of the sets of grooves 400 or 500 is optional. That is, there may be only grooves 500 , or only housing grooves 400 , or there may be both. The thrust runner 220 may include a profile 504 which corresponds with a matching profile, not shown, on the shaft 208 . The profile 504 transfers torque from the shaft 208 to the thrust runner 220 .
[0030] The housing grooves 400 and the grooves 500 are shown as being substantially parallel with the shaft 208 . This arrangement allows for bi-directional flow of fluids across the thrust runner 220 . The housing grooves 400 and the grooves 500 are also shown as being rectangular grooves in the thrust runner 220 and the thrust housing 219 ; however, it should be appreciated that the grooves may have any geometry so long as the grooves 400 and 500 allow fluids to flow past the thrust runner 220 during operation, such as: rounded, triangular, polygonal, etc. The Fluid flows through the housing grooves 400 and the grooves 500 to stabilize the thrust runner 220 as it rotates in the thrust housing 219 .
[0031] FIGS. 6A-6C show views of the upper thrust bearing 222 . The upper thrust bearing 222 , as shown, has six load pads 304 symmetrically located around the bearing; however, there could be any number of load pads 304 . The upper thrust bearing 222 includes a bore 600 through which the shaft 208 and lubricating fluid passes. Further, the upper thrust bearing 222 includes a gap 602 between each of the load pads 304 that provide an area for the lubricating fluid to flow during operation. The load pads 304 in operation may have a fluid film, not shown, between the thrust runner 220 and the load pads 304 that aids in reducing friction between the two surfaces. The fluid film is formed from a thin layer of the lubricating fluid on each of the load pads 304 . The fluid film reduces friction between the thrust runner 220 and the load pads 304 during rotation.
[0032] In operation, the wellbore 100 is formed and the formation is perforated. Production fluids then fill the wellbore 100 . To enhance recovery of production fluids to the surface of the wellbore 100 , the artificial lift assembly 108 is run into the wellbore on the conveyance 106 . Before the artificial lift assembly 108 is lowered into the wellbore 100 , the motor seal 112 is filled with the lubricating fluid. The artificial lift assembly 108 is lowered into the wellbore 100 and may be submersed in wellbore fluids. The intake 114 and/or pump 116 allow the wellbore fluids and/or the production fluids to enter the artificial lift assembly 108 . When at a desired location, the motor 110 actuates in order to operate the pump 116 .
[0033] The actuation of the motor 110 turns the motor shaft which transfers torque to the shaft 208 . The torque in the shaft 208 causes the shaft 208 to rotate within the motor seal 112 . The rotation of the shaft 208 is transferred to the thrust runner 220 thereby causing the thrust runner 220 to rotate. The radial bearing 226 substantially prevents the thrust runner 220 from contacting the thrust housing 219 during rotation. The flow path which consists of either the housing grooves 400 , the grooves 500 , or both, circulates the lubricating fluid upon rotation of the thrust runner 220 . The rotation of the thrust runner 220 creates a pressure drop in the flow path across the thrust runner 220 causing the lubricating fluids in the thrust chamber 206 to move toward the pump 116 . Additionally, the lubricating fluid may flow past the thrust runner 220 toward the motor in a space, not shown, between the shaft 208 and the thrust runner 220 which replenishes the lubricating fluid on the motor side of the thrust runner 220 . As the speed of rotation increases the pressure drop across the thrust runner 220 increases thereby increasing the circulation speed.
[0034] Initially the motor 110 and thrust runner 220 begin to rotate and cause shaft 208 and thrust runner 220 to move up toward the pump 116 . The upward movement creates an up-thrust force which is absorbed by the upper thrust bearing 222 . The fluid film between the thrust runner 220 and the upper thrust bearing 222 transfers it to the load pads 304 while reducing friction between the thrust runner and the upper thrust bearing 222 . The load pads 304 transfer the up thrust to the upper thrust bearing 222 which in turn transfers the load to the thrust housing 219 . This prevents the up thrust from transferring up the shaft 208 and into the pump 116 . The circulation of the lubricating fluids past the radial bearing 226 decreases turbulence around the load pads 304 . The decrease in turbulence decreases the vibration and wear on the load pads 304 during operation, thereby enhancing the life of the thrust runner 220 and the upper thrust bearing 222 .
[0035] As the motor 110 continues to turn the shaft 208 and the pump shaft, the pump eventually begins to push wellbore fluids and/or production fluids toward the surface of the wellbore 100 . This pushing/pumping of the fluids toward the surface of the wellbore causes reactive down thrust on the pump shaft and in turn the shaft 208 . The down thrust transfers down the shaft 208 to the thrust runner 220 . The thrust runner 220 transfers the down thrust to the down thrust bearing 224 . The down thrust bearing 224 absorbs the load in the same way as the upper thrust bearing absorbed the up thrust. The circulation of the lubricating fluid reduces the turbulence around the down thrust bearing 224 in the same manner as described above.
[0036] The circulation of the lubricating fluid by the thrust runner causes circulation between the seal portions 200 , 202 , and 204 and the thrust chamber 206 through the series of ports 218 . The lubricating fluid, which is pushed upward by the rotation of the thrust runner 220 , flows up a first port 250 toward the seal portion 204 . The lubricating fluid enters chamber 214 near the upper end of the chamber 214 . The additional lubricating fluid in the full chamber 214 causes lubricating fluid to flow up the second port 252 and into the chamber 214 of the seal portion 202 . This circulation continues and eventually the lubricating fluid interacts with the wellbore fluids and/or production fluids near the connection between the seal portion 200 and the intake 114 and/or the pump 116 . The interaction between the wellbore fluids and the lubricating fluids causes some wellbore fluids to enter the motor seal 112 . As discussed above, the wellbore fluids may have a higher specific gravity than the lubricating fluids. Thus during circulation, the wellbore fluids will flow toward the bottom of each of the seal portions 200 , 202 , 204 . As the wellbore fluids reach the bottom of the first seal portion 200 some of the wellbore fluids will flow down a third port 254 and into the seal portion 202 . The mechanical seals 216 prevent the wellbore fluids from flowing out of the seal portions 200 , 202 , and 204 along the shaft 208 . The ports 250 , 252 and 254 are bidirectional, that is fluids can flow up or down the ports 250 , 252 and 254 . The lubricating fluids will substantially remain in the upper portions of the seal portions 200 , 202 , and 204 . Because the first port 250 has an entry/exit near the upper portion of the seal portion 204 , wellbore fluids and production fluids are substantially prevented from entering the thrust chamber 206 . The circulation of the lubricating fluids in the seal portions 200 , 202 , and 204 , with the lubricating fluids in the thrust chamber 206 , increase the cooling of the lubricating fluids in the thrust chamber. That cooling enhances the life of the upper thrust bearing 222 and the down thrust bearing 224 . The flow path in the thrust chamber 206 and the radial bearing allow the artificial lift assembly 108 to operate longer in a wellbore 100 than conventional motor seals.
[0037] In one embodiment, the radial bearing clearance between the thrust housing 219 and the thrust runner 220 is in the range of 0.002 to 0.008 inches. In an alternative embodiment, the radial bearing clearance is less than or equal to 0.008 inches. In yet another alternative embodiment, the radial bearing clearance is greater than or equal to 0.002 inches. The radial bearing effect may be lost if the radial bearing clearance is too large.
[0038] In an alternative embodiment, the motor seal comprises of a bag motor seal rather than the labyrinth motor seal described above. The operation of the thrust chamber 206 is the same as described above; however, the motor seals operate with bags.
[0039] In yet another embodiment, the flow path are in the shape of spiraled grooves, not shown. Thus, the housing grooves 400 or the grooves 500 , or both, have a spiraled configuration. As described above, either housing grooves 400 or grooves 500 are optional. The spiraled flow path decreases the pressure drop across the thrust runner 220 . The spiraled flow pushes the lubricating fluid in one direction past the thrust runner 220 . The spiraled flow may be arranged to push the lubricating fluids toward the pump 116 , thereby creating a circulation as described above. Further, the spiraled flow path may push the lubricating fluids toward the motor 110 . As the lubricating fluids flow toward the motor 110 , they circulate with fluid in the motor 110 . This circulation in the motor 110 increases the life and reliability of the motor 110 during the lifting operation. The circulation between the seal portions 200 , 202 , and 204 and the thrust chamber 206 remain substantially the same as described above.
[0040] In yet another embodiment, one of the sets of grooves 400 or 500 may be spiraled while the other sets of grooves 400 or 500 is substantially parallel with the shaft 208 .
[0041] While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.
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A method and apparatus for stabilizing a thrust chamber and circulating fluids within a motor seal is described herein. The apparatus includes a thrust chamber having a thrust runner and a radial bearing. A flow path exists through the radial bearing which stabilizes the thrust runner and circulates fluids in the thrust chamber. The flow path may consist of a plurality of grooves located adjacent to the radial bearing.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This is a Continuation Application that claims the benefit of prior U.S. Continuation application Ser. No. 09/638,934 filed Aug. 15, 2000 by Hans G. Franke et al. entitled “Extrusion Die for Biodegradable Material with Die Orifice Modifying Device and Flow Control Device”, now U.S. Pat. No. 6,533,973 which is a continuation and claims benefit of U.S. application Ser. No. 09/035,200 filed Mar. 5, 1998 by Hans G. Franke et al. entitled “Extrusion Die for Biodegradable Material with Die Orifice Modifying Device and Flow Control Device” now U.S. Pat. No. 6,183,672B1.
BACKGROUND OF THE INVENTION
This invention relates generally to the formation of shaped objects from expanded biodegradable materials, and, in particular, to an extrusion die for ultimately forming sheets of biodegradable material.
Biodegradable materials are presently in high demand for applications in packaging materials. Commonly used polystyrene (“Styrofoam” (Trademark)), polypropylene, polyethylene, and other non-biodegradable plastic-containing packaging materials are considered detrimental to the environment and may present health hazards. The use of such non-biodegradable materials will decrease as government restrictions discourage their use in packaging applications. Indeed, in some countries in the world, the use of styrofoam (trademark) is already extremely limited by legislation. Biodegradable materials that are flexible, pliable and non-brittle are needed in a variety of packaging applications, particularly for the manufacture of shaped biodegradable containers for food packaging. For such applications, the biodegradable material must have mechanical properties that allow it to be formed into and hold the desired container shape, and be resistant to collapsing, tearing or breaking.
Starch is an abundant, inexpensive biodegradable polymer. A variety of biodegradable based materials have been proposed for use in packaging applications. Conventional extrusion of these materials produces expanded products that are brittle, sensitive to water and unsuitable for preparation of packaging materials. Attempts to prepare biodegradable products with flexibility, pliability, resiliency, or other mechanical properties acceptable for various biodegradable packaging applications have generally focused on chemical or physio-chemical modification of starch, the use of expensive high amylose starch or mixing starch with synthetic polymers to achieve the desired properties while retaining a degree of biodegradability. A number of references relate to extrusion and to injection molding of starch-containing compositions.
U.S. Pat. No. 5,397,834 provides biodegradable, thermoplastic compositions made of the reaction product of a starch aldehyde with protein. According to the disclosure, the resulting products formed with the compositions possess a smooth, shiny texture, and a high level of tensile strength, elongation, and water resistance compared to articles made from native starch and protein. Suitable starches which may be modified and used according to the invention include those derived, for example, from corn including maize, waxy maize and high amylose corn; wheat including hard wheat, soft wheat and durum wheat; rice including waxy rice; and potato, rye, oat, barley, sorghum, millet, triticale, amaranth, and the like. The starch may be a normal starch (about 20-30 wt-% amylose), a waxy starch (about 0-8 wt-% amylose), or a high-amylose starch (greater than about 50 wt-% amylose).
U.S. Pat. Nos. 4,133,784, 4,337,181, 4,454,268, 5,322,866, 5,362,778, and 5,384,170 relate to starch-based films that are made by extrusion of destructurized or gelatinized starch combined with synthetic polymeric materials. U.S. Pat. No. 5,322,866 specifically concerns a method of manufacture of biodegradable starch-containing blown films that includes a step of extrusion of a mixture of raw unprocessed starch, copolymers including polyvinyl alcohol, a nucleating agent and a plasticizer. The process is said to eliminate the need of pre-processing the starch. U.S. Pat. No. 5,409,973 reports biodegradable compositions made by extrusion from destructurized starch and an ethylene-vinyl acetate copolymer.
U.S. Pat. No. 5,087,650 relates to injection-molding of mixtures of graft polymers and starch to produce partially biodegradable products with acceptable elasticity and water stability.
U.S. Pat. No. 5,258,430 relates to the production of biodegradable articles from destructurized starch and chemically-modified polymers, including chemically-modified polyvinyl alcohol. The articles are said to have improved biodegradability, but retain the mechanical properties of articles made from the polymer alone.
U.S. Pat. No. 5,292,782 relates to extruded or molded biodegradable articles prepared from mixtures of starch, a thermoplastic polymer and certain plasticizers.
U.S. Pat. No. 5,095,054 concerns methods of manufacturing shaped articles from a mixture of destructurized starch and a polymer.
U.S. Pat. No. 4,125,495 relates to a process for manufacture of meat trays from biodegradable starch compositions. Starch granules are chemically modified, for example with a silicone reagent, blended with polymer or copolymer and shaped to form a biodegradable shallow tray.
U.S. Pat. No. 4,673,438 relates to extrusion and injection molding of starch for the manufacture of capsules.
U.S. Pat. No. 5,427,614 also relates to a method of injection molding in which a non-modified starch is combined with a lubricant, texturing agent and a melt-flow accelerator.
U.S. Pat. No. 5,314,754 reports the production of shaped articles from high amylose starch.
EP published application No. 712883 (published May 22, 1996) relates to biodegradable, structured shaped products with good flexibility made by extruding starch having a defined large particle size (e.g., 400 to 1500 microns). The application exemplifies the use of high amylose starch and chemically-modified high amylose starch.
U.S. Pat. No. 5,512,090 refers to an extrusion process for the manufacture of resilient, low density biodegradable packaging materials, including loose-fill materials, by extrusion of starch mixtures comprising polyvinyl alcohol (PVA) and other ingredients. The patent refers to a minimum amount of about 5% by weight of PVA.
U.S. Pat. No. 5,186,990 reports a lightweight biodegradable packaging material produced by extrusion of corn grit mixed with a binding agent (guar gum) and water. Corn grit is said to contain among other components starch (76-80%), water (12.5-14%), protein (6.5-8%) and fat (0.5-1%). The patent teaches the use of generally known food extruders of a screw-type that force product through an orifice or extension opening. As the mixture exits the extruder via the flow plate or die, the super heated moisture in the mixture vaporizes forcing the material to expand to its final shape and density.
U.S. Pat. No. 5,208,267 reports biodegradable, compressible and resilient starch-based packaging fillers with high volumes and low weights. The products are formed by extrusion of a blend of non-modified starch with polyalkylene glycol or certain derivatives thereof and a bubble-nucleating agent, such as silicon dioxide.
U.S. Pat. No. 5,252,271 reports a biodegradable closed cell light weight loose-fill packaging material formed by extrusion of a modified starch. Non-modified starch is reacted in an extruder with certain mild acids in the presence of water and a carbonate compound to generate CO 2 . Resiliency of the product is said to be 60% to 85%, with density less than 0.032 g/cm 3 .
U.S. Pat. No. 3,137,592 relates to gelatinized starch products useful for coating applications produced by intense mechanical working of starch/plasticizer mixtures in an extruder. Related coating mixtures are reported in U.S. Pat. No. 5,032,337 which are manufactured by the extrusion of a mixture of starch and polyvinyl alcohol. Application of thermomechanical treatment in an extruder is said to modify the solubility properties of the resultant mixture which can then be used as a binding agent for coating paper.
Biodegradable material research has largely focused on particular compositions in an attempt to achieve products that are flexible, pliable and non-brittle. The processes used to produce products from these compositions have in some instances, used extruders. For example, U.S. Pat. No. 5,660,900 discloses several extruder apparatuses for processing inorganically filled, starch-bound compositions. The extruder is used to prepare a moldable mixture which is then formed into a desired configuration by heated molds.
U.S. Pat. No. 3,734,672 discloses an extrusion die for extruding a cup shaped shell made from a dough. In particular, the die comprises an outer base having an extrusion orifice or slot which has a substantial horizontal section and two upwardly extending sections which are slanted from the vertical. Further, a plurality of passage ways extend from the rear of the die to the slot in the face of the die. The passage way channels dough from the extruder through the extrusion orifice or slot.
Previously, in order to form clam shells, trays and other food product containers, biodegradable material was extruded as a flat sheet through a horizontal slit or linear extrusion orifice. The flat sheet of biodegradable material was then pressed between molds to form the clam shell, tray or other food package. However, these die configurations produced flat sheets of biodegradable material which were not uniformly thick, flexible, pliable and non-brittle. The packaging products molded from the flat sheets also had these negative characteristics.
As the biodegradable material exited the extrusion orifice, the biodegradable material typically had greater structural stability in a direction parallel to the extrusion flow direction compared to a direction transverse to the extrusion flow direction. In fact, fracture planes or lines along which the sheet of biodegradable material was easily broken, tended to form in the biodegradable sheet as it exited from the extrusion orifice. Food packages which were molded from the extruded sheet, also tended to break or fracture along these planes.
Therefore, there is a need for a process which produces a flexible, pliable and non-brittle biodegradable material which has structural stability in both the longitudinal and transverse directions
SUMMARY OF THE INVENTION
According to one aspect of the present invention, there is provided a extrusion die through which biodegradable material can be extruded which has structural stability in both the longitudinal and transverse directions of the material, which has a flow control device which controls flow of biodegradable material through the extrusion die, and which allows the inner and outer walls of the extrusion orifice to be adjusted relative to each other to modify the circumferencial wall thickness of the cylindrical extrudate.
According to one embodiment of the invention, the die extrudes a tubular shaped structure which has its greatest structural stability in a direction which winds helically around the tubular structure. Thus, at the top of the tubular structure, the direction of greatest stability twists in one direction while at the bottom the direction of greatest stability twists in the opposite direction. This tubular structure is then pressed into a sheet comprised of two layers having their directions of greater stability approximately normal to each other. This 2-ply sheet is a flexible, pliable and non-brittle sheet with strength in all directions.
According to another embodiment of the present invention, the flow rate of the biodegradable material is regulated at a location upstream from the orifice and at the orifice itself to provide complete control of extrusion parameters. In particular, the head pressure of the biodegradable material behind the extrusion orifice is controlled to produce an extrudate having desired characteristics.
According to a further embodiment of the invention, an annular extrusion die allows the inner and outer walls of the extrusion orifice to be adjusted relative to each other to modify the circumferencial wall thickness of the cylindrical extrudate.
According to one aspect of the present invention, there is provided an extrusion die for extruding biodegradable material, the extrusion die comprising: a mandrel; an outer member positioned near the mandrel; an extrusion orifice between the mandrel and the outer member; a member in communication with at least one defining member of the extrusion orifice, wherein the member is capable of producing relative movement between the outer member and the mandrel, wherein the relative movement has a component transverse to an extrusion direction of biodegradable material through the extrusion orifice; a flow control device which controls flow of biodegradable material through the extrusion die; and a positioning device which positions the outer member and the mandrel relative to each other.
According to another aspect of the invention, there is provided an extrusion die for extruding biodegradable material, the extrusion die comprising: a cylindrical mandrel; a cylindrical outer ring positioned around the mandrel; an annular extrusion orifice between the mandrel and the outer ring; a member in communication with at least one defining member of the annular extrusion orifice which produces angular relative movement between the outer ring and the mandrel; a flow control device which controls flow of biodegradable material through the extrusion die, wherein the flow control device comprises a mechanism which translates the outer ring to adjust the width of the annular extrusion orifice; and a positioning device which positions the outer ring and the mandrel relative to each other.
According to a further aspect of the invention, there is provided an extrusion die for extruding biodegradable material, the extrusion die comprising: a mandrel; an outer member positioned near the mandrel; an extrusion orifice between the mandrel and the outer member; a mounting plate having a flow bore which conducts biodegradable material toward the extrusion orifice, wherein the mandrel is fixedly mounted to the mounting plate and the outer member is movably mounted to the mounting plate; a shearing member which moves the outer member relative to the mandrel in a direction having a component transverse to an extrusion direction of biodegradable material through the extrusion orifice; a flow control device which controls flow of biodegradable material through the extrusion die, wherein the flow control device comprises a flow control channel upstream of the extrusion orifice, wherein the flow control channel throttles flow of the biodegradable material through the die, wherein the mandrel is attached to the mounting plate with at least one spacer between, wherein the mounting plate and the mandrel define the flow control channel; and a positioning device which positions the outer member and the mandrel relative to each other, wherein the positioning device comprises a shifting device for moving the outer member and the mandrel relative to each other and a fixing device which fixes the relative positions of the outer member and the mandrel.
According to another aspect of the invention, there is provided an improved process for the extrusion of biodegradable material wherein the extrusion comprises flowing the biodegradable material in a flow direction through an orifice, the improvement comprising: moving or shearing the biodegradable material, in a direction having a component transverse to the flow direction, during extrusion; controlling the flow rate of biodegradable material through the extrusion die during extrusion, wherein the controlling comprises adjusting the head pressure of the biodegradable material in the extrusion die and adjusting at least one cross-sectional area of a biodegradable material flow path within the extrusion die; and modifying the orifice geometry.
According to another aspect of the invention, there is provided a process for manufacturing biodegradable shaped products of increased strength, the process comprising: extruding a biodegradable material, wherein the extruding comprises moving the biodegradable material in a first direction through an orifice to produce an extrudate; modifying the orifice geometry; shearing the biodegradable material, in a second direction having a component transverse to the first direction, during the extruding; controlling the flow rate of biodegradable material through the extrusion die during the extruding, wherein the controlling comprises adjusting the cross-sectional area of an extrusion orifice and wherein the controlling further comprises adjusting the cross-sectional area of a biodegradable material flow path at a location upstream of the extrusion orifice; compressing the extrudate; and molding the compressed extrudate of biodegradable material into a structure.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is better understood by reading the following description of non-limitative embodiments, with reference to the attached drawings wherein like parts in each of the several figures are identified by the same reference character, and which are briefly described as follows.
FIG. 1 is a cross-sectional view of an embodiment of the invention fully assembled.
FIG. 2 is a cross-sectional view of an embodiment of the die fully assembled with centering and flow control devices.
FIG. 3 is an exploded perspective view of the several parts which comprise the die shown in FIG. 2 .
FIG. 4 is a cross-sectional exploded view of a mandrel, mounting plate and spacers.
FIG. 5 is a cross-sectional exploded view of a gap adjusting ring, a bearing housing and an end cap.
FIG. 6 is an exploded cross-sectional view of a seal ring, an outer ring and a die wheel.
FIG. 7A is a cross-sectional side view of an embodiment of the invention having a motor and belt for rotating an outer ring about a mandrel.
FIG. 7B is an end view of the embodiment of the invention as shown in FIG. 7 A.
FIG. 8 is a side view of a system for producing molded objects from biodegradable material, the system comprising an extruder, a rotating extrusion die, a cylindrical extrudate, rollers, and molding devices.
FIG. 9 is a flow chart of a process embodiment of the invention.
FIG. 10A is a perspective view of a cylindrical extrudate of biodegradable material having helical extrusion lines.
FIG. 10B is a perspective view of a sheet of biodegradable material produced from the extrudate shown in FIG. 10 A.
FIG. 11 is an end view of an embodiment of the invention for rotating the die wheel of the rotating die, the device having a rack gear.
FIG. 12A is a perspective view of a cylindrical extrudate having sinusoidal extrusion lines.
FIG. 12B is a top view of a sheet of biodegradable material produced from the extrudate shown in FIG. 12 A.
FIG. 13 is an end view of a device for rotating the die wheel of an embodiment of the invention wherein the system comprises a worm gear.
FIG. 14A is a perspective view of an extrudate of biodegradable material wherein the extrudate is cylindrical in shape and has zigzag extrusion lines.
FIG. 14B is a top view of a sheet of biodegradable material produced from the extrudate shown in FIG. 14 A.
It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of the inventions scope, as the invention may admit to other equally effective embodiments.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, a cross-section view of an embodiment of the invention is shown. The die 1 is made up of several discrete annular members which share the same longitudinal central axis 3 . A mounting plate 20 is located in the center of the die 1 and is the member to which most of the remaining parts are attached. At one end of the mounting plate 20 , an extruder adapter 10 is attached for connecting the die 1 to an extruder (not shown). A backplate 11 is attached between the extruder adapter 10 and the mounting plate 20 . At an end opposite to the extruder adapter 10 , several spacers 100 are positioned in counter sunk holes in the mounting plate 20 at various locations equidistant from the longitudinal central axis 3 . A mandrel 30 has counter sunk holes which correspond to those in the mounting plate 20 . The mandrel 30 is fixed to the mounting plate 20 with the spacers 100 between, the spacers being inserted into the respective counter sunk holes. On the same side of the mounting plate 20 as the mandrel 30 , a seal ring 40 is inserted into an annular spin channel 22 of the mounting plate 20 . At the periphery of the mounting plate 20 , the mounting plate 20 has a bearing portion 71 which extends around the seal ring 40 . An end cap 80 is attached to the distal end of the bearing portion 71 of the mounting plate 20 to lock the seal ring 40 in the spin channel 22 . An outer ring 50 is attached to the seal ring 40 around the outside of the mandrel 30 to form an extrusion orifice 5 between the outer ring 50 and the mandrel 30 . Finally, a die wheel 90 is attached to the outer ring 50 . As described more fully below, a motor and drive system drive the die wheel 90 to rotate the outer ring 50 about the mandrel 30 .
Biodegradable material is pushed through the die 1 under pressure by an extruder (not shown) which is attached to the extruder adapter 10 . The biodegradable material passes through flow bore 23 which conducts the material through the extruder adapter 10 and the mounting plate 20 to a central location at the backside of the mandrel 30 . The biodegradable material is then forced radially outward through a disc-shaped cavity called a flow control channel 4 which is defined by the mounting plate 20 and the mandrel 30 . From the flow control channel 4 , the biodegradable material is pushed through the extrusion orifice 5 defined by the mandrel 30 and the outer ring 50 . According to one embodiment of the invention, the biodegradable material is forced through the extrusion orifice 5 , the die wheel 90 , outer ring 50 and seal ring 40 are rotated relative to the stationary mounting plate 20 and mandrel 30 .
Referring to FIGS. 2 and 3, cross-sectional and exploded views, respectively, of an embodiment of the invention with orifice shifting and flow control devices are shown. The die 1 is made up of several discrete annular members which share the same longitudinal central axis 3 . A mounting plate 20 is located in the center of the die 1 and is the member to which most of the remaining parts are attached. At one end of the mounting plate 20 , an extruder adapter is attached for connecting the die 1 to an extruder (not shown). A gap adjusting ring 60 is placed concentrically around the cylindrical exterior of the mounting plate 20 . A bearing housing 70 lies adjacent the gap adjusting ring 60 and the mounting plate 20 . A seal ring 40 is placed within the bearing housing 70 and is inserted into an annular spin channel of the mounting plate 20 . At an end opposite to the extruder adapter 10 , several spacers 100 are positioned in counter sunk holes in the mounting plate 20 at various locations equidistant from the longitudinal central axis 3 . A mandrel 30 has counter sunk holes which correspond to those in the mounting plate 20 . The mandrel is fixed to the mounting plate 20 with the spacers 100 between. An outer ring 50 is attached to the seal ring 40 around the outside of the mandrel 30 to form an extrusion orifice 5 between the outer ring 50 and the mandrel 30 . Finally, a die wheel 90 is attached to the outer ring 50 for rotating the outer ring 50 about the mandrel 30 .
Referring to FIG. 4, a cross section of the mounting plate 20 , spacers 100 and the mandrel 30 are shown disassembled. The mounting plate 20 is basically a solid cylinder with a cylindrical flow bore 23 cut in the middle along the longitudinal central axis 3 . One end of the mounting plate 20 comprises a mounting shoulder 21 for engagement with the extruder adapter 10 (shown in FIGS. 2 and 3 ). Opposite the mounting shoulder 21 , the mounting plate 20 has a annular spin channel 22 for receiving the seal ring 40 (shown in FIGS. 2 and 3 ). Between the cylindrical flow bore 23 at the center and the spin channel 22 , the mounting plate 20 has a disc-shaped flow surface 25 . The mounting plate 20 also has several mounting plate counter sunk holes 24 for receiving spacers 100 such that the counter sunk holes 24 are drilled in the flow surface 25 . In FIG. 4, only two counter sunk holes 24 are shown because the view is a cross section along a plane which intersects the longitudinal central axis 3 . All of the mounting plate counter sunk holes 24 are equidistant from each other and from the longitudinal central axis 3 .
According to one embodiment of the invention, the mandrel 30 is a bowl shaped structure having a base 31 and sides 32 . As shown in FIG. 4, the mandrel 30 is oriented sideways so that the central axis of the mandrel is collinear with the longitudinal central axis 3 of the die. Unlike the mounting plate 20 , which has a flow bore 23 through the center, the mandrel 30 has a solid base 31 . The outside surface of the base 31 is a base flow surface 33 . The mandrel 30 has several countersunk holes 34 which are cut in the base flow surface 33 . In FIG. 4, only two mandrel countersunk holes 34 are shown because the view is a cross-section along a plane which intersects the longitudinal central axis 3 . All of the mandrel countersunk holes 34 are equidistant from each other and from the central axis 3 . The inside of the mandrel 30 is hollowed out to reduce its overall weight.
Spacers 100 are used to mount the mandrel 30 to the mounting plate 20 . Each of the spacers 100 comprise male ends 102 for insertion into mounting plate and mandrel countersunk holes 24 and 34 . Of course, the outside diameter of the male ends 102 is slightly smaller than the inside diameters of mounting plate and mandrel countersunk holes 24 and 34 . Between the male ends 102 , each of the spacers 100 comprise a rib 101 which has an outside diameter larger than the inside diameters of the mounting plate and mandrel countersunk holes 24 and 34 . The rib 101 of each spacer 100 has a uniform thickness in the longitudinal direction to serve as the spacer mechanism between the assembled mounting plate and mandrel.
The mandrel 30 is attached to the mounting plate 20 with mandrel bolts 36 . The mandrel bolts 36 extend through the base 31 of the mandrel 30 , through the spacers 100 and into treaded portions in the bottom of the mounting plate counter sunk holes 24 . While the heads of the mandrel bolts 36 could be made to rest firmly against the inside of the base 31 of the mandrel, in the embodiment shown, the mandrel bolts extend through risers 35 so that the heads of the mandrel bolts 36 are more accessible from the open end of the mandrel 30 . In this embodiment, one end of each of the risers 35 rests securely against the inside of the mandrel base 31 while the other end of each riser is engaged by the head of a mandrel bolt 36 .
Referring to FIG. 5, a cross-sectional view of the gap adjusting ring 60 , the bearing housing 70 , and the end cap 80 are shown disassembled. The gap adjusting ring 60 is a ring shaped member having a longitudinal central axis 3 and an inner diameter slightly greater than the outside diameter of the mounting plate 20 (shown in FIGS. 2 and 3 ). The gap adjusting ring 60 also has several lock screws 61 which extend through an inner portion 62 of the gap adjusting ring 60 for engagement with the mounting plate 20 once the gap adjusting ring 60 is placed around the outside of the mounting plate 20 . Also, the gap adjusting ring 60 has an outer portion 63 for engagement with the bearing housing 70 . At the outer edge of the outer portion 63 , the gap adjusting ring 60 has shifting lugs 64 which are attached via lug bolts 65 . In the embodiment shown, four shifting lugs 64 are attached to the outer portion 63 of the gap adjusting ring 60 . The shifting lugs 64 are spaced around the gap adjusting ring 60 so that one is at the top, bottom, and sides, respectively. The shifting lugs 64 extend from the outer portion 63 in a longitudinal direction for positioning engagement with the bearing housing 70 . The shifting bolts 66 poke through the shifting lugs 64 in the part of the shifting lugs 64 which extend from the outer portion 63 in the longitudinal direction. The shifting bolts 66 poke through in a direction from outside the die toward the longitudinal central axis 3 . Finally, the gap adjusting ring 60 has threaded holes 67 at various locations around the outer portion 63 for receiving screws 74 .
The bearing housing 70 is an annular ring which has a longitudinal central axis 3 . The bearing housing 70 has a bearing portion 71 and a support portion 72 . The support portion 72 is annular with is greatest cross-section in a direction transverse to the longitudinal central axis 3 . The bearing housing 70 is attachable to the gap adjusting ring 60 by the support portion 72 which engages the outer portion 63 of the gap adjusting ring 60 . In the embodiment shown, this engagement between the bearing housing 70 and the gap adjusting ring 60 is accomplished by screws 74 between these two members. The support portion 72 has several slip holes 75 which protrude through the support portion 72 in a longitudinal direction. In one embodiment, twelve slip holes 75 are positioned equidistant from each other around the support portion 72 and are positioned equidistant from the longitudinal central axis 3 . The inside diameter of each slip hole 75 is larger than the outside diameter of screws 74 so that there is substantial “play” between the screws 74 and the slip holes 75 . While the slip holes 75 are larger than the screws 74 , the slip holes 75 are small enough so that the heads of the screws 74 securely engage the support portion 72 of the bearing housing 70 .
The other major part of the bearing housing 70 is the bearing portion 71 which is an annular section having its greatest thickness in the longitudinal direction. The interior surface of the bearing portion 71 is a bearing surface 76 for engaging lateral support bearings 42 (shown in FIG. 6 ). The bearing surface 76 supports the lateral support bearings 42 in a plane normal to the longitudinal central axis 3 . Protruding from the bearing surface 76 near the support portion 72 , the bearing housing 70 has a bearing housing lateral support flange 73 which supports a lateral support bearing 42 of the seal ring 40 (shown in FIG. 6 ).
When the bearing housing 70 is attached to the gap adjusting ring 60 , the relative positions of the two devices may be adjusted. In particular, during assembly, the shifting bolts 66 of the gap adjusting ring 60 are relaxed to provide enough space for the support portion 72 of the bearing housing 70 . The bearing housing 70 is then placed directly adjacent the gap adjusting ring 60 with the support portion 72 within the extended portions of shifting lugs 64 . The screws 74 are then inserted through the slip holes 75 and loosely screwed into threaded holes 67 in the gap adjusting ring 60 . The shifting bolts 66 are then adjusted to collapse on the support portion 72 of the bearing housing 70 . The shifting bolts 66 may be adjusted to push the bearing housing 70 off center relative to the gap adjusting ring 60 . Because the slip holes 75 are larger than the screws 74 , the shifting bolts 66 freely push the bearing housing 70 in one direction or the other. By varying the pressure of the shifting bolts 66 against the outer surface of the bearing housing 70 , the bearing housing 70 , seal ring 40 and outer ring 50 may be perturbed from their original positions to more desirable positions. Once the desired relative position of the bearing housing 70 to the gap adjusting ring 60 is obtained, the screws 74 are tightened to firmly attach the two members.
The end cap 80 is preferably a ring which has a longitudinal central axis 3 . The interior portion of the end cap 80 is a stabilizer 81 and the exterior is a fastener flange 82 . Fastener holes 83 are drilled in the fastener flange 82 for inserting fasteners which secure the end cap 80 to the bearing portion 71 of the bearing housing 70 . The outside diameter of the stabilizer 81 of the end cap 80 is slightly smaller than the inside diameter of the bearing portion 71 of the bearing housing 70 . This allows the stabilizer 81 to be inserted into the bearing portion 71 . At the distal end of the stabilizer 81 , there is an end cap lateral support flange 84 which supports a lateral support bearing 42 (shown in FIG. 6 ). Therefore, when the end cap 80 is securely fastened to the bearing housing 70 , the bearing housing lateral support flange 73 and the end cap lateral support flange 84 brace the lateral support bearings 42 (shown in FIG. 6) against movement in the longitudinal directions.
Referring to FIG. 6, a cross-sectional view of the seal ring 40 , the outer ring 50 and the die wheel 90 are shown disassembled. The seal ring 40 is a cylindrical member having a longitudinal central axis 3 . The seal ring 40 has an interior diameter which decreases from one end to the other. At the end of the seal ring 40 which has the smallest inside diameter, the seal ring 40 has a notch 47 for engaging the outer ring 50 as discussed below. On the outside of the seal ring 40 , there are four superior piston rings 41 for engaging the mounting plate 20 and the end cap 80 (both shown in FIGS. 2 and 3 ). The seal ring 40 also comprises two lateral support bearings 42 . The lateral support bearings 42 are separated by a bearing spacer flange 43 which is positioned between the two lateral support bearings 42 . The seal ring 40 further comprises two retaining rings 44 which are positioned on the outsides of the lateral support bearings 42 . Thus, the seal ring 40 is assembled by slipping one of the lateral support bearings 42 over each end of the seal ring 40 until they are each adjacent opposite sides of the bearing spacer flange 43 . Next, retaining rings 44 are slipped over each end of the seal ring 40 until they snap into grooves 45 at the outsides of the lateral support bearings 42 . Thus, the lateral support bearings 42 are secured between the bearing spacer flange 43 and the retaining rings 44 . Finally, the superior piston rings 41 are placed in piston slots 46 .
The outer ring 50 is a cylindrical member having a longitudinal central axis 3 . The outer ring 50 has a ring portion 51 and a fastener flange 52 . Longitudinal holes are cut through the fastener flange 52 for inserting fasteners which secure the outer ring 50 to an end of the seal ring 40 . The outside diameter of the ring portion 51 is slightly smaller than the inside diameter of the notch 47 of the seal ring 40 . This allows the outer ring 50 to be assembled to the seal ring 40 by inserting the ring portion 51 into the notch 47 . The inside diameter of the ring portion 51 tapers from the end which attaches to the seal ring 40 to the other. At the end of the ring portion 51 having the smallest inside diameter, the outer ring 50 comprises a lip 53 which defines one side of the extrusion orifice 5 (shown in FIG. 2 ).
The die wheel 90 is a cylindrical member with a wheel flange 92 and a drive section 93 . Holes are drilled through the wheel flange 92 for inserting wheel fasteners 91 which secure the die wheel 90 and the outer ring 50 to the seal ring 40 . The drive section 93 is a device which engages a drive mechanism for rotating the die wheel 90 . In the embodiment shown in the figure, the drive section is a pulley for engaging a drive belt.
Assembly of the complete die 1 is described with reference to FIGS. 2 and 3. First, the extruder adapter 10 is secured to the mounting plate 20 with a back plate 11 between. Next, with further reference to FIG. 4, several spacers 100 are placed in the mandrel 30 by inserting a male end 102 of each spacer 100 into a mandrel counter sunk hole 34 , until all the mandrel counter sunk holes 34 have a spacer 100 . The mandrel 30 is then placed adjacent the mounting plate 20 with the protruding male ends 102 of the spacers 100 being inserted into the mounting plate counter sunk holes 24 . The mandrel 30 is then attached to the mounting plate 20 with spacers 100 between the mandrel bolts 36 . In particular, the risers 35 are slipped over the shanks of the mandrel bolts 36 and the mandrel bolts 36 are inserted through the mandrel base 31 , the mandrel counter sunk holes 34 , the spacers 100 , and the mounting plate counter sunk holes 24 . The bottoms of the mounting plate counter sunk holes 24 are threaded so that the mandrel bolts 36 may be screwed into the mounting plate 20 . The mandrel bolts 36 are then screwed into the threaded bottoms of each mounting plate counter sunk hole 24 to fasten the mandrel 30 to the mounting plate 20 . With further reference to FIG. 5, the gap adjusting ring 60 is slipped over the exterior of the mounting plate 20 . The lock screws 61 are then tightened against the exterior of the mounting plate 20 . The bearing housing 70 is then positioned with the support portion 72 against the outer portion 63 of the gap adjusting ring 60 . The shifting bolts 66 are adjusted to center the bearing housing 70 about the longitudinal central axis 3 and the screws inserted through slip holes 75 and tightened into the threaded holes 67 of the gap adjusting ring 60 . Next, with further reference to FIG. 6, the seal ring 40 having superior piston rings 41 , lateral support bearings 42 and retaining rings 44 attached thereto, is rotatably attached to the bearing housing 70 . In particular, the seal ring 40 is inserted into the bearing housing 70 and then into the spin channel 22 of the mounting plate 20 . The seal ring 40 is pushed all the way into the spin channel 22 of the mounting plate 20 until the first of the lateral support bearings 42 rests firmly against the bearing housing lateral support flange 73 . In this position, two of the four superior piston rings 41 form a seal between the seal ring 40 and the spin channel 22 of the mounting plate 20 . The seal ring 40 is held in this position by inserting the stabilizer 81 of the end cap 80 into the bearing portion 71 of the bearing housing 70 . The end cap 80 is pushed all the way into the bearing housing 70 until the end cap lateral support flange 84 contacts the second of the lateral support bearings 42 of the seal ring 40 . Once in place, the end cap 80 is fixed to the bearing housing 70 by inserting fasteners through the fasteners holes 83 of the fastener flange 82 and into the bearing portion 71 of the bearing housing 70 . The interior surface of the stabilizer 81 of the end cap 80 engages the remaining two superior pistons rings 41 of the seal ring 40 so that the seal ring 40 is completely stabilized and allowed to spin freely about the longitudinal central axis 3 . With the end cap 80 securely fastened to the bearing housing 70 , the seal ring 40 is securely fastened in the lateral direction between the lateral support flanges 73 and 84 . With the seal ring 40 securely in place, the outer ring 50 and die wheel 90 are then attached to the end which protrudes from the mounting plate 20 . In particular, the ring portion 51 of the outer ring 50 is inserted into the notch 47 of the seal ring 40 and the wheel flange 91 of the die wheel 90 is positioned adjacent the fastener flange 52 of the outer ring 50 . Wheel fasteners 91 are then inserted through the wheel flange 92 and the fastener flange 52 and locked into the seal ring 40 .
Once assembled, both the extruder adapter 10 and the mounting plate 20 further comprise a flow bore 23 which extends from the extruder (not shown) to the flow surface 25 , as shown in FIGS. 2 and 4. Thus, the die 1 operates such that biodegradable extrudate material is pushed by the extruder through the flow bore 23 until it reaches the base flow surface 33 of the mandrel 30 . The biodegradable extrudate then flows radially outward around the spacers 100 between the flow surface 25 of the mounting plate 20 and the base flow surface 33 of the mandrel 30 . This disc-like space between the mounting plate 20 and the mandrel 30 is the flow control channel 4 . From the flow control channel 4 , the biodegradable extrudate then enters a cylindrical space between the seal ring 40 and the mandrel 20 and is pushed through this space toward the extrusion orifice 5 between the mandrel 30 and the outer ring 50 . As the biodegradable extrudate moves toward the extrusion orifice 5 , the die wheel 90 is rotated to rotate the outer ring 50 and seal ring 40 around the stationary mandrel 30 . Thus, the biodegradable extrudate is twisted by the rotating outer ring 50 . As the extrudate exits the extrusion orifice 5 , a tubular product of twisted biodegradable material is produced. As described fully below, because the seal ring 40 is rotatably mounted within the bearing housing 70 , the seal ring 40 may be made to rotate about the mandrel 30 as the extrudate is pushed through the orifice 5 .
Flow of the biodegradable material through the die 1 is controlled in two ways: (1) adjusting the width of the flow control channel 4 , and (2) controlling the size of the extrusion orifice 5 . Regarding the flow control channel 4 , as noted above, biodegradable material is passed from the extruder through a flow bore 23 in the mounting plate 20 until it reaches the base flow surface 33 of the mandrel 30 . From the central location, the biodegradable material is pushed radially outward between the base flow surface 33 of the mandrel 30 and the flow surface 25 of the mounting plate 20 . Of course, as the biodegradable material flows between the surfaces through the flow control channel 4 , it passes around each of the spacers 100 which separate the mandrel 30 and the mounting plate 20 . The width of the flow control channel 4 is adjusted by using spacers which have larger or smaller ribs 101 (See FIG. 4 ). In particular, if it is desirable to decrease flow of the biodegradable material through the flow control channel 4 , spacers 100 having ribs 101 which are relatively thin in the longitudinal direction are inserted between the mounting plate 20 and the mandrel 30 . Alternatively, if it is desirable to increase a flow rate of biodegradable material through the flow control channel 4 , spacers 100 having ribs 101 with relatively larger thicknesses in the longitudinal direction are inserted between the mounting plate 20 and the mandrel 30 . Therefore, in a preferred embodiment, the die 1 has several sets of spacers 100 which may be placed between the mounting plate 20 and the mandrel 30 to control the width of the flow control channel 4 .
Additionally, flow of the biodegradable material through the extrusion orifice 5 is controlled by altering the width of the extrusion orifice 5 . The thickness of the extrusion orifice 5 between the mandrel lip 37 and the outer ring lip 53 is adjusted by sliding the gap adjusting ring 60 , the bearing housing 70 , the seal ring 40 , and the outer ring 50 along the longitudinal central axis 3 out away from the stationary mandrel 30 . Since the interior diameter of the ring portion 51 of the outer ring 50 is tapered from the end which attaches to the seal ring 40 , the outer ring 50 has its smallest interior diameter at the outer ring lip 53 . To produce a biodegradable extrudate with a very thin wall thickness, the gap adjusting ring 60 is pushed all the way onto the mounting plate 20 until the outer ring lip 53 is directly opposite the mandrel lip 37 . To produce a thicker biodegradable extrudate, the gap adjusting ring 60 is moved slightly away from the mounting plate 20 along the longitudinal central axis 3 in the direction of direction arrow 6 (shown in FIG. 2 ), so that the outer ring lip 53 is positioned beyond the mandrel lip 37 . Thus, a wider section of the ring portion 51 is adjacent the lip 37 of the mandrel 30 so that the extrusion orifice 5 is thicker. Once the desired orifice size is obtained, lock screws 61 are screwed into the gap adjusting ring 60 to re-engage the mounting plate 20 . This locks the gap adjusting ring 60 , the bearing housing 70 , the seal ring 40 , and the outer ring 50 in place to ensure the thickness of the extrusion orifice 5 remains constant during operation. A thicker extrusion orifice 5 increases flow through the die.
Referring to FIGS. 7A and 7B, side and end views of portions of an embodiment of the invention for rotating the outer ring of the die are shown, respectively. The mandrel 30 is attached to the mounting plate 20 so that the mandrel 30 is locked in place. The seal ring 40 and outer ring 50 are rotatably mounted around the mandrel 30 . A die wheel 90 is also attached to the outer ring 50 . All of these members have longitudinal central axes which are collinear with longitudinal central axis 3 . The device also has a motor 110 which has a drive axis 113 which is parallel to longitudinal central axis 3 . Attached to a drive shaft of motor 110 , there is a drive wheel 111 . The motor 110 and drive wheel 111 are positioned so that drive wheel 111 lies in the same plane as the die wheel 90 , the plane being perpendicular to the longitudinal central axis 3 . Opposite the drive wheel 111 , the system further has a snubber wheel 115 which is also positioned in the perpendicular plane of the drive wheel 111 and the die wheel 90 . The snubber wheel 115 has a snubber axis 116 which is also parallel to the longitudinal central axis 3 . Thus, the drive wheel 111 and the snubber wheel 115 are positioned at opposite ends of the system with the die wheel 90 between. A drive belt 112 engages the drive wheel 111 , the die wheel 90 and the snubber wheel 115 . The snubber wheel 115 has no drive mechanism for turning the drive belt 112 . Rather, the snubber wheel 115 is an idle wheel which only turns with the drive belt 112 when the drive belt 112 is driven by the motor 110 . The snubber wheel 115 serves only to evenly distribute forces exerted by the drive belt 112 on the die wheel 90 . Because the drive wheel 111 and snubber wheel 115 are positioned on opposite sides of the die wheel 90 , forces exerted by the drive belt 112 on the die wheel 90 are approximately equal in all transverse directions. If the snubber wheel 115 were not placed in this position and the drive belt 112 engaged only the drive wheel 111 and the die wheel 90 , a net force would be exerted by the drive belt 112 on the die wheel 90 in the direction of the motor 110 . This force would pull the die wheel 90 and thus the outer ring 50 out of center from its position about the stationary mandrel 30 . Of course, this would have the detrimental effect of producing an extrudate tube of biodegradable material which would have a wall thickness greater on one side than on the other. Therefore, the snubber wheel 115 is positioned in the system to prevent the die wheel 90 from being pulled from its central location around the mandrel 30 .
In a preferred embodiment, the drive belt 112 is a rubber belt. Alternatively, chains or mating gears may be used to mechanically connect the motor 110 to the die wheel 90 . A typical one-third horse power electric motor is sufficient to produce the necessary torque to drive the drive belt 112 . Further, the gear ratios between the drive wheel 111 and the die wheel 90 are such that the die wheel 90 may preferably rotate at approximately 15 rotations per minute. Depending on the particular gear system employed, alternative embodiments require more powerful motors.
Referring to FIGS. 8 and 9, system and method embodiments of the invention are described for producing a biodegradable final product, respectively. The system 130 has a hopper 131 into which biodegradable material is initially placed (step 140 ). The hopper 131 supplies (step 141 ) biodegradable material to an extruder 132 which pressurizes (step 142 ) and cooks (step 143 ) the biodegradable material. The extruder 132 pushes (step 144 ) the biodegradable material through an extrusion die 1 . The extrusion die 1 is an embodiment of the rotating extrusion die of the present invention and is driven by a motor 110 with a drive belt 112 . As the biodegradable material is pushed (step 144 ) through the extrusion die 1 , an outer ring of the die 1 is rotated (step 145 ) around an inner mandrel. The biodegradable material is pushed (step 146 ) from the extrusion die 1 through an extrusion orifice to form a cylindrical extrudate 15 . The cylindrical extrudate 15 is then pulled (step 147 ) from the extrusion orifice by a pair of press rollers 133 . Next, the press rollers 133 flatten (step 148 ) the cylindrical extrudate 15 into a sheet 17 of biodegradable material. The sheet 17 of biodegradable material is then molded (step 149 ) between corresponding molds 134 to form the biodegradable material into final products. The shaped final products are then deposited in bin 135 .
According to alternative embodiments of the invention, it is desirable to stretch the cylindrical extrudate 15 as it exits the extrusion orifice 5 . This is accomplished by rotating the press rollers 133 slightly faster than a speed necessary to keep pace with the exit rate of the cylindrical extrudate 15 from the extrusion orifice 5 . As the press rollers 133 rotate faster, the cylindrical extrudate 15 is pulled by the press rollers 133 from the extrusion orifice 5 so that the cylindrical extrudate 15 is stretched in the longitudinal direction before it is flattened into a flat 2-ply sheet.
Referring to FIG. 10A, an example of a biodegradable extrudate from the extrusion die of the present invention is shown. The extrudate 15 exits from the extrusion orifice 5 (see FIG. 2 for die components) as a cylindrical structure. Typically, while not meant to be limited thereby, it is believed the polymer chains of the biodegradable material are aligned in the direction of extrusion to produce an extrudate which has its greatest structural integrity in the extrusion direction. If the extrudate 15 exits the extrusion orifice 5 as the outer ring 50 is rotated around the mandrel 30 , the extrudate 15 orients along extrusion lines 16 .
Preferably, the cylindrical extrudate 15 is collapsed to form a sheet of biodegradable material having two extrudate layers. As shown in FIG. 10B, a perspective view of a sheet of extrudate material produced from the tubular extrudate of FIG. 10A is shown. The sheet 17 is produced simply by rolling the extrudate 15 through two rollers to compress the tubular extrudate 15 into the sheet 17 . The sheet 17 consequently comprises extrusion lines 16 which form a cross-hatch pattern. The sheet 17 is comprised of two layers, one of which previously formed one side of the tubular extrudate 15 while the second layer of the sheet 17 previously formed the other side of the extrudate 15 . Therefore, because the extrusion lines 16 were helically wound around the extrudate 15 , when the sheet 17 is formed, the extrusion lines 16 of the two layers run in opposite directions. The extrusion line angle 18 of the extrusion lines 16 may be adjusted by controlling the flow rate of the extrudate 15 from the extrusion orifice 5 of the die 1 (see FIG. 2 for die components), and controlling the speed of angular rotation of the outer ring 50 about the mandrel 30 . If it is desirable to increase the extrusion line angle 18 , the die is adjusted to increase the angular speed of the outer ring 50 relative to the mandrel 30 , and/or to decrease the flow rate of the extrusion material from the extrusion die. As noted above, the flow rate of the biodegradable material through the die is controlled by adjusting the size of the extrusion orifice 5 and/or the flow control channel 4 .
According to one embodiment of the invention, the outer ring 50 of the die 1 is made to rotate in both clockwise and counter-clockwise directions about the mandrel 30 to produce a biodegradable extrudate wherein the extrusion lines have a wave pattern. To produce this extrudate, the outer ring 50 is first rotated in one direction and then rotated in the opposite direction. Depending on the rates of direction change, the pattern produced is sinusoidal, zigzag, or boxed. The periods and amplitudes of these wave patterns are adjusted by altering the rate of rotation of the outer ring 50 and the flow rate of the biodegradable material through the extrusion die 1 .
Many different drive systems are available for alternating the direction of rotation of the outer ring 50 . For example, the motor 110 of the embodiment shown in FIGS. 7A and 7B is made to alternate directions of rotation. As the motor 110 changes directions of rotation, the drive wheel 111 , drive belt 112 and die wheel 90 consequently change directions.
Alternatively, as shown in FIG. 11, the die wheel 90 is a spur gear with radial teeth parallel to the longitudinal central axis 3 . The teeth of the die wheel 90 are engaged by teeth of a rack gear 117 . Opposite the rack gear 117 , an idler gear 124 is engaged with the die wheel 90 to prevent the rack gear 117 from pushing the outer ring 50 out of alignment with the mandrel 30 (See FIG. 2 ). The rack gear 117 is mounted on a slide support 118 and moves linearly along a slide direction 120 which is transverse to the longitudinal central axis 3 . The slide support 118 is connected to a drive wheel 111 via a linkage 114 . In particular, one end of the linkage 114 is connected to an end of the slide support 118 and the other end of the linkage 114 is connected to the drive wheel 111 at its periphery. The slide support 118 is braced by brackets 125 so that slide support 118 is only allowed to move along slide direction 120 . As the drive wheel 111 rotates clockwise around rotation direction 119 , the linkage 114 pushes and pulls the slide support 118 back and forth along slide direction 120 . The back and forth movement of the slide support 118 rotates the die wheel 90 and the outer ring 50 alternatively in clockwise and counter-clockwise directions.
Since the linkage 114 is connected to the drive wheel 111 at its periphery, as noted above, the alternative clockwise and counter-clockwise rotation of the outer ring 50 is a sinusoidal oscillatory type motion. Thus, this embodiment of the invention produces a biodegradable extrudate 15 with extrusion lines 16 which have a sine wave pattern as shown in FIG. 12 A. As described above, the extrudate 15 is rolled into a sheet 17 having two layers as shown in FIG. 12 B. The period of the sine waves are identified by reference character 19 and the amplitude is identified by reference character 14 . The period 19 and amplitude 14 of extrusion lines 16 may be adjusted by controlling the flow rate of the extrudate 15 from the extrusion orifice 5 of the die 1 (see FIG. 2 for die components), and controlling the speed of angular rotation of the outer ring 50 about the mandrel 30 . If it is desirable to increase the period of the sine waves, the die is adjusted to decrease the angular speed of the outer ring 50 relative to the stationary mandrel 30 , and/or to increase the flow rate of the extrusion material from the extrusion orifice 5 . As noted above, the flow rate of the biodegradable material through the die is controlled by adjusting the size of the extrusion orifice 5 and/or the flow control channel 4 . Further, if it is desirable to increase the amplitude 14 of the sine waves, the angular range of motion of the outer ring 50 is increased so that the outer ring 50 rotates further around the stationary mandrel 30 before it stops and changes direction. While many parameters may be altered to produce this result, a simple modification is to use a drive wheel 111 which has a relatively larger diameter.
A similar embodiment of the invention which rotates the outer ring in clockwise and counter-clockwise directions is shown in FIG. 13 . As before, the die wheel 90 is a spur gear with radial teeth parallel to the longitudinal central axis 3 . The teeth of the die wheel 90 are engaged by teeth of a worm gear 122 which is positioned with its axis of rotation transverse to the longitudinal central axis 3 . Opposite the worm gear 122 , an idler gear 124 is engaged with the die wheel 90 to prevent the worm gear 122 from pushing the outer ring 50 out of alignment with the mandrel 30 (see FIG. 2 ). The worm gear 122 is driven by a motor 110 with a transmission 121 between. A drive shaft 123 of the motor 110 is connected to a power side of the transmission 121 and the worm gear 122 is connected to a drive side of the transmission 121 . While the motor 110 rotates the drive shaft 123 in only one direction, the transmission 121 rotates the worm gear 122 in both clockwise and counter-clockwise directions. Further, in one embodiment, the transmission 121 rotates the worm gear 122 at different speeds even though the motor 110 operates at only one speed. A similar embodiment comprises a motor and transmission which drive a pinion gear which engages the die wheel 90 . Since the worm gear 122 is rotated at a constant speed in each direction, this embodiment of the invention produces a biodegradable extrudate which has a zigzag pattern of extrusion lines 16 .
Since the motor 110 runs at constant angular velocity and the transmission is used to change the direction of rotation of the worm gear 122 , the alternative clockwise and counter-clockwise rotation of the outer ring 50 is an oscillatory type motion. Thus, this embodiment of the invention produces a biodegradable extrudate 15 with extrusion lines 16 which have a linear oscillatory wave pattern or zigzag wave pattern as shown in FIG. 14 A. As described above, the extrudate 15 is rolled into a sheet 17 having two layers as shown in FIG. 14 B. The period of the zigzag waves are identified by reference character 19 and the amplitude is identified by reference character 14 . The period 19 and amplitude 14 of extrusion lines 16 is adjusted by controlling the flow rate of the extrudate 15 from the extrusion orifice 5 of the die 1 (see FIG. 2 for die components), and controlling the speed of angular rotation of the outer ring 50 about the mandrel 30 . If it is desirable to increase the period of the zigzag waves, the die is adjusted to decrease the angular speed of the outer ring 50 relative to the stationary mandrel 30 , and/or to increase the flow rate of the extrusion material from the extrusion orifice 5 . As noted above, the flow rate of the biodegradable material through the die is controlled by adjusting the size of the extrusion orifice 5 and/or the flow control channel 4 . Further, if it is desirable to increase the amplitude 14 of the zigzag waves, the angular range of motion of the outer ring 50 is increased so that the outer ring 50 rotates further around the stationary mandrel 30 before it stops and changes direction. While many parameters may be altered to produce this result, a simple modification is to control the transmission 121 to allow the worm gear 122 to run longer in each direction before reversing the direction.
While the particular embodiments for extrusion dies as herein shown and disclosed in detail are fully capable of obtaining the objects and advantages herein before stated, it is to be understood that they are merely illustrative of the preferred embodiments of the invention and that no limitations are intended by the details of construction or design herein shown other than as described in the appended claims.
LIST OF CHARACTER DESIGNATIONS
1 . Die
3 . Longitudinal Central Axis
4 . Flow Control Channel
5 . Extrusion Orifice
6 . Direction Arrow
10 . Extruder Adapter
11 . Back Plate
14 . Extrusion Wave Amplitude
15 . Extrudate
16 . Extrusion Lines
17 . Sheet
18 . Extrusion Line Angle
19 . Extrusion Wave Period
20 . Mounting Plate
21 . Mounting Shoulder
22 . Spin Channel
23 . Flow Bore
24 . Countersunk Holes
25 . Flow Surface
30 . Mandrel
31 . Mandrel Base
32 . Mandrel Sides
33 . Base Flow Surface
34 . Countersunk Holes
35 . Risers
36 . Mandrel Bolts
37 . Mandrel Lip
40 . Seal Ring
41 . Superior Piston Rings
42 . Lateral Support Bearings
43 . Bearing Spacer Flange
44 . Retaining Rings
45 . Grooves
46 . Piston Slots
47 . Notch
50 . Outer Ring
51 . Ring Portion
52 . Fastener Flange
53 . Outer Ring Lip
55 . Outer Die Structure
60 . Gap Adjusting Ring
61 . Lock Screws
62 . Inner Portion
63 . Outer Portion
64 . Centering Lugs
65 . Lug Bolts
66 . Centering Bolts
67 . Threaded Holes
70 . Bearing Housing
71 . Bearing Portion
72 . Support Portion
73 . Lateral Support Flange
74 . Screws
75 . Slip Holes
76 . Bearing Surface
80 . End Cap
81 . Stabilizer
82 . Fastener Flange
83 . Fastener Holes
84 . Lateral Support Flange
90 . Die Wheel
91 . Wheel Fastener
92 . Wheel Flange
93 . Drive Section
100 . Spacer
101 . Rib
102 . Male Ends
110 . Motor
111 . Drive Wheel
112 . Drive Belt
113 . Drive Axis
114 . Linkage
115 . Snubber Wheel
116 . Snubber Axis
117 . Rack Gear
118 . Slide Support
119 . Rotation Direction
120 . Slide Direction
121 . Transmission
122 . Worm Gear
123 . Drive Shaft
124 . Idler Gear
125 . Brackets
130 . Biodegradable Product Producing System
131 . Hopper
132 . Extruder
133 . Press Rollers
134 . Molds
135 . Bin
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An extrusion die for extruding biodegradable material, the extrusion die including: a mandrel; an outer member positioned near the mandrel; an extrusion orifice between the mandrel and the outer member; a member in communication with at least one defining member of the extrusion orifice, wherein the member is capable of producing relative movement between outer member and the mandrel, wherein the relative movement has a component transverse to an extrusion direction of biodegradable material through the extrusion orifice; a flow control device which controls flow of biodegradable material through the extrusion die; and a positioning device which positions the outer member and the mandrel relative to each other.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to semiconductor devices and more particular to a trenched field effect transistor especially suitable for low voltage switching applications.
[0003] 2. Description of the Prior Art
[0004] Field effect transistors (FETs) are well known, as are metal oxide semiconductor field effect transistors (MOSFETs); such transistors are often used for power applications. There is a need for power transistors for relatively low voltage applications, i.e. typically under 50 volts, that have low current leakage blocking capability.
[0005] Examples of trench field effect transistors suitable for such applications are disclosed in “Comparison of Ultra Low Specific On Resistance UMOSFET Structures . . . ” by Syau et al., IEEE Transactions on Electron Devices , Vol. 41, No. 5, May 1994. Inter alia, this publication describes the so-called INVFET structure of present FIG. 1, which corresponds to FIG. 1( b ) of the publication. Present FIG. 1 shows only a portion of a single transistor including the polysilicon (polycrystalline silicon) gate electrode 10 which in this case is N-type polysilicon which is insulated by a gate oxide layer 12 on its sides and bottom in a trench 14 and insulated on its top side by an oxide layer 18 . The trench 14 extends through the N+ doped source region 22 through the P doped base region 24 and into the N+ doped drain region 26 . The drain electrode 30 is formed on the underside of the drain region 26 and the source electrode 32 formed on the top side of the source region.
[0006] Also described in FIG. 1( c ) of this article and shown here in present FIG. 2 is the somewhat similar so-called EXTFET which is identical to the INVFET except for having an additional N− doped drift region 36 formed underlying the P doped base region 24 . For both of these devices the P base region 24 is formed by diffusion (hence does not exhibit uniform doping) and is fairly heavily doped. It is believed that a typical surface concentration of the P base region 24 is 10 17 /cm 3 .
[0007] These devices are both intended to avoid full depletion of the P base (body) region 24 . They each have the gate electrode 10 doped to the same conductivity type as is the drain region 26 (i.e. N type) as shown in FIGS. 1 and 2. The “mesa” width, i.e. the width of the source region between two adjacent trenches, is typically 3 μm and a typical cell pitch for an N-channel device is about 6 μm. Blocking is accomplished by a quasi-neutral (undepleted) PN junction at a V gs (gate source voltage) of zero. The ACCUFET (see Syau et al. article) offers the best specific on resistance at the expense of poor blocking capability, while the INVFET and EXTFET offer improved blocking at the expense of increased specific on resistance.
[0008] As is well known, a power MOSFET should have the lowest possible on-state specific resistance in order to minimize conduction losses. On-state resistance is a well known parameter of the efficiency of a power transistor and is the ratio of drain-to-source voltage to drain current when the device is fully turned on. On-state specific resistance refers to resistance times cross sectional area of the substrate carrying the drain current.
[0009] However, these prior art devices do not provide the optimum low on-state specific resistance in combination with blocking state low current leakage.
SUMMARY
[0010] This disclosure is directed to a MOS semiconductor device suitable especially for low voltage power application where low leakage blocking capability is desirable. In accordance with the invention, the off-state blocking of a trenched field effect transistor is achieved by a gate controlled barrier region between the source and drain. Similar to the above described INVFET, forward conduction occurs through an inversion region between the source and the drain (substrate). Unlike the INVFET, however, blocking is achieved by a gate controlled depletion barrier and not by a quasi-neutral PN junction. The depletion barrier is formed and controlled laterally and vertically so as to realize the benefits of ultra-low on-state specific resistance combined with the low current leakage blocking. Advantageously, this structure is relatively easily fabricated and has blocking superior to that of prior art ACCUFET devices, with low leakage current at zero applied gate-source voltage. Moreover, in the blocking state there is no quasi-neutral PN junction, and therefore, like the ACCUFET, this structure offers the advantage of containing no parasitic bipolar PN junction.
[0011] The present device's on-state specific resistance is comparable to that of the ACCUFET, and like the ACCUFET offers on-state specific resistance superior to that of the INVFET and EXTFET as described in the above mentioned article by Syau et al.
[0012] In an N-channel embodiment of the present invention, an N+ drain region underlies a lightly doped P− body region which is overlain by an N+ source region. The body region is formed by lightly doped epitaxy with uniform or almost uniform doping concentration, typically in a range of 10 14 to 10 16 /cm 3 . The gate electrodes are formed in trenches which extend through the source region, through the body region, and partially into the drain (substrate) region. Alternatively, the gate electrodes do not extend into the drain region. The polysilicon gate electrodes themselves are P doped, i.e. having a doping type the same as that of the body region. Additionally, the mesas (holding the source regions) located between adjacent gate electrode trenches are less than 1.5 μm wide, and the cell pitch is less than 3 μm.
[0013] Advantageously in the blocking state the epitaxial P body region is depleted due to the applied drain-source bias V ds , and hence a punch-through type condition occurs vertically. However, lateral gate control combined with the narrow mesa width (under 1.5 μm) increases the effective depletion barrier to majority carrier flow and prevents conduction. Thus, the present device is referred to herein as the PT-FET for “punch-through field effect transistor”.
[0014] Thus the blocking characteristics are determined by barrier-limited majority-carrier current flow and not by avalanche breakdown. In accordance with the invention, a complementary P-channel device is implemented and has advantages comparable to those of the above described N-channel device.
[0015] The above described embodiment has a floating body region, thus allowing bidirectional operation. In another embodiment a body contact region is provided extending into the body region from the principal surface of the semiconductor structure, thus allowing a source region to body region short via the source metallization for forward blocking-only applications.
[0016] Thus advantageously the present PT-FET has a fully depleted (punch-through) lightly doped body region at a small applied drain-source voltage. This differs from the P body region in the above described INVFET and EXTFET which must, by design, be undepleted to avoid punch-through. Advantageously, the threshold voltage is low due to the lightly doped P body region and the device has an on-state specific resistance similar to that of the ACCUFET and superior to that of the INVFET or EXTFET.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] [0017]FIG. 1 shows a prior art INVFET.
[0018] [0018]FIG. 2 shows a prior art EXTFET.
[0019] [0019]FIG. 3 shows an N-channel PT-FET in accordance with the present invention.
[0020] [0020]FIG. 4A shows operation of the present PT-FET in equilibrium.
[0021] [0021]FIG. 4B shows operation of the present PT-FET in the blocking (off) state with an applied drain-source voltage.
[0022] [0022]FIG. 4C shows operation of the present PT-FET in the on state.
[0023] [0023]FIG. 5 shows dimensions and further detail of one embodiment of a PT-FET.
[0024] [0024]FIGS. 6, 7 and 8 show three termination and poly runner structures suitable for use with the present PT-FET.
[0025] [0025]FIGS. 9A, 9B and 9 C show process steps to fabricate a PT-FET in accordance with the present invention.
[0026] [0026]FIGS. 10A and 10B show two top side layouts for a PT-FET.
[0027] [0027]FIG. 11 shows a P-channel PT-FET.
[0028] [0028]FIG. 12 shows another embodiment of a PT-FET with a body contact region and the body region shorted to the source.
[0029] Similar reference numbers herein in various figures refer to identical or similar structures.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] [0030]FIG. 3 shows a cross section (not to scale) of a portion of a trenched N-channel PT-FET in accordance with the present invention. It is to be understood that FIG. 2, like the other figures herein, is not to scale and that furthermore the various doped semiconductor regions shown herein, which are illustrated as precisely defined regions delineated by borderlines, are conventional representations of doped regions having in reality gradient dopant levels at their edges. Moreover, as is well known in the art and as described further below, typically power MOSFETs include a large number of cells, the cells having various shapes such as square, circular, hexagonal, linear or others. These cells are evident in a top side view, several of which are provided below. In terms of cell layout, the PT-FET is conventional and may be fabricated in any one of a number of well known cell structures. The present illustrations are therefore typically of only one cell or a portion of two cells as delineated by the gate trenches, and are not intended to illustrate an entire power transistor which would typically include hundreds or thousands of such cells.
[0031] Moreover, certain well known elements of such trenched MOSFETs are not shown in certain of the present drawings. For instance, the metallization which connects to the gate electrodes is typically not shown as being outside the plane of the present cross sectional drawings. Also, the termination portions of the transistors are only shown in certain of the drawings below; in others the termination portions are outside the area depicted in the drawings.
[0032] [0032]FIG. 3 shows one embodiment of an N-channel PT-FET including a drain (substrate) region 40 which is N+ doped to have a resistivity of e.g. 0.002 Ω-cm. Formed immediately over the drain region 40 is a P− doped body region 42 having a doping concentration in the range of e.g. 10 14 to 10 16 /cm 3 and a typical doping concentration of 10 15 /cm 3 .
[0033] Overlying the body region 42 is the N+ doped source region 44 which is doped to a concentration of e.g. 2×10 19 /cm 3 . A conventional metallized drain contact 48 is formed the backside of the semiconductor substrate. Formed in the upper portion of the semiconductor structure are trenches 50 A, 50 B, which respectively hold P+ doped polysilicon gate electrodes 52 A, 52 B which are each doped P-type to a maximum attainable value. (It is to be understood that gate electrodes 52 A, 52 B are connected to each other outside the plane of the drawing). Each trench 50 A, 50 B is lined with gate oxide layer 54 e.g. 500 Å thick (a typical range is 400 to 800 Å) to insulate the polysilicon gate electrodes from the silicon sidewalls and bottom of the trenches 50 A, 50 B.
[0034] Not depicted in this illustration are the passivation layer (typically boro-phosphosilicate glass BPSG) and the top side source contact metallization. In this case the body region 42 is a “floating region”, having no electrical contact made thereto. This structure has been found especially suitable for high current, low voltage switching applications, i.e. less than 25 volts.
[0035] The principle of operation of this device is illustrated in FIGS. 4A, 4B and 4 C. FIG. 4A illustrates equilibrium, and FIG. 4B illustrates operation in the blocking (off) state. Thus the gate-source bias voltage (V gs ) is equal to zero in both FIGS. 4A and 4B. In the blocking state the drain-source voltage (V ds ) is greater than or equal to zero, since operation of the device of FIG. 3 is bidirectional. FIG. 4A illustrates the body depletion for the situation where the drain-source voltage is equal to zero. (It is to be understood that there is plus (+) charge depletion in the N+ source and drain regions which is not drawn for simplicity.) This is an equilibrium state in terms of the charge distribution, as shown in FIG. 4A.
[0036] In FIG. 4B, the drain-source voltage is greater than zero while the gate-source voltage is still equal to zero. In this case the body region is fully depleted. The leakage current is controlled by an electron energy barrier formed within the body depletion region as shown. The leakage current is reduced to acceptably low levels (e.g., 1% of that of an ACCUFET) by the P-doped polysilicon gate electrodes 52 A, 52 B. It has been found by the present inventors that a P-type polysilicon gate electrode for an N-channel device (that is, the polysilicon gate electrode having the same conductivity type as the adjacent body region) is highly beneficial. The P-type polysilicon gate electrode allows the body region to remain fully depleted while it enhances the energy barrier to reduce leakage to acceptable levels (levels superior to those of the ACCUFET).
[0037] Thus majority carrier current flow is provided without any deleterious PN junction behavior. There is also no need to short the source region 44 to the body region 42 , hence allowing bidirectional operation of the PT-FET. Thus the gate control of the barrier allows low current leakage, superior to that of the prior art ACCUFET, because the barrier is larger due to the doping type of the lightly doped body region 42 .
[0038] [0038]FIG. 4C illustrates the on state conduction which is typically the situation with the gate-source voltage being greater than the transistor threshold voltage and the drain-source voltage is greater than zero.
[0039] In this case as shown the inversion regions are along the trench 50 A, 50 B side walls which conduct majority carrier through the inversion region. Current flow takes place when the drain-source voltage is greater than zero, in the direction shown by the arrow. Advantageously the lightly doped body region 42 allows a low threshold voltage, while in addition the on-state specific resistance is superior to that of the INVFET or the EXTFET, and comparable to that of the ACCUFET.
[0040] [0040]FIG. 5 shows additional detail of an N channel PT-FET which is otherwise similar to that of FIGS. 3 and 4. Also illustrated in FIG. 5 is the conventional (passivation) layer 58 which is BPSG overlying each polysilicon gate electrode, and the metal, e.g. aluminum, source contact. Also shown in FIG. 5 are exemplary dimensions for the gate oxide 54 thickness (500 Å) and the source region 44 thickness (0.25 μm). The typical trench 50 A, 50 B depth is 2.1 μm, which extends through the source region 44 and body region 42 and partially into the substrate region 40 . An exemplary thickness of the substrate (drain region 40 ) is 500 μm.
[0041] As illustrated, the mesa (the silicon between two adjacent gate trenches) is e.g. 1 μm (under 1.5 μm) in width while each trench 50 A, 50 B is 1 μm (under 1.5 μm) in width, thus allowing an exemplary 2 μm to 3 μm pitch per cell.
[0042] [0042]FIGS. 3, 4 and 5 each only illustrate one cell or a portion of two cells in the active portion of a typical multi-cell PT-FET. FIG. 6 illustrates a first embodiment of a PT-FET with at the left side a termination region 64 . At the right side is a “poly runner” region 68 for contacting low-resistivity metal (not shown) to the relatively higher resistivity gate electrode material. FIG. 6 shows a number of cells (additional cells are omitted, as suggested by the broken lines) in the active region of the device. The left side termination region 64 includes, adjacent the leftmost trench 50 C, the absence of any N+ source region. Also present in termination region 64 is a BPSG layer 58 A. Source contact 60 is located between BPSG portions 58 A, 58 . In the right side poly runner region 68 (mesa), again there is no source region to the right of trench 50 E. This mesa provides a wide contact region for running metallization to select regions of polysilicon for the purpose of lowering total gate resistance. Also shown in FIG. 6 is field oxide region 62 in termination region 64 , underlying BPSG layer 58 A. Optionally the field oxide is also present in the poly runner region 68 . Polysilicon structure 52 F includes a gate runner to the polysilicon gate electrode 52 E of the adjacent cell in trench 50 E.
[0043] [0043]FIG. 7 shows a second PT-FET having a termination region and poly runner region which differ from those of FIG. 6 in two ways. First, P+ regions 62 A, 62 B are provided in both the left side termination and right side poly runner regions 64 , 68 . These P+ regions 62 A, 62 B prevent leakage in the relatively wide poly runner region 68 and prevent inversion in both the termination 64 and poly runner regions 68 .
[0044] Additionally, the N+ source regions 44 A, 44 B are present respectively in the termination and poly runner regions. In this case the polysilicon (“poly”) runner in the right side poly runner region 68 extends over to contact the N+ region 44 B in the poly runner region 68 , with a contact 60 B made to that N+ region for purposes of electrostatic (ESD) robustness.
[0045] [0045]FIG. 8 shows a third PT-FET similar to that of FIG. 7 in having the N+ regions 44 A, 44 B respectively in the termination and poly runner regions, but not having a P+ region in the termination or poly runner regions. Additionally the N+ region 44 B in the right side poly runner region 68 does not have an exterior metallized contact (is floating) to prevent leakage in the relatively wide mesa region. FIG. 8 is similar to FIGS. 6 and 7 in that polysilicon structure 52 F includes a runner to the gate electrode 52 E in adjacent trench 50 E.
[0046] A process for fabricating an N-channel PT-FET is illustrated in FIGS. 9A through 9C. Beginning in FIG. 9A, an N+ doped silicon substrate 40 (having a resistivity e.g. 0.001-0.005 Ω-cm) is provided, on which is grown epitaxially a lightly doped P− region 42 having a doping concentration of 10 15 /cm 3 which becomes the body region. A typical final thickness of this P-epitaxial layer 42 after all processing is 2 μm.
[0047] Then in several steps shown in FIG. 9B, an active region mask (not shown) is formed over the principal surface of the epitaxial layer 42 to pattern the field oxide in the termination region and optionally in the poly runner region. The active region mask patterns the field oxide in the termination region and opens the areas for active cells. Next a source mask is formed and patterned, and then through the openings in the source mask the N+ source region 44 is implanted and diffused to a thickness (depth) of approximate 0.25 μm and a final surface doping concentration of e.g. 2×10 19 /cm 3 . The N+ source region 44 , due to the source region mask, is not implanted in the termination 64 and poly runner regions 68 (as shown in FIG. 6 for instance) in some embodiments. In the embodiments of FIGS. 7 and 8 the N+ source region implant is a maskless step which occurs before the field oxide/active mask steps. In the embodiment of FIG. 6, the source region implant occurs after the active mask steps.
[0048] Then in several steps in FIG. 9C, the upper surface of the P-doped epitaxial layer 42 is masked and the mask is patterned to define the trench locations. The trenches are then conventionally anisotropically etched by e.g. dry etching to a depth of approximately 2.1 μm.
[0049] After the trenches are etched, a gate oxide layer 54 e.g. 500 Å thick (in a range of 400 to 800 Å) is formed lining the trenches and over the entire surface of the epitaxial layer 42 .
[0050] Then a layer of polysilicon is deposited filling the trenches and over the entire surface of the epitaxial layer. The polysilicon is then heavily doped with a P type dopant before it is patterned. A mask is then applied to the upper surface of the polysilicon and the mask is patterned and the polysilicon etched to define the gate electrodes and the polysilicon runners (as described above) connecting the gate electrodes.
[0051] In the embodiment of FIG. 7, the P+ region 62 A, 62 B is implanted using a mask by e.g. a high energy implant, either before or after the trenches are etched and filled.
[0052] After patterning of the polysilicon gate structures 52 A, 52 B, a layer of BPSG 58 is formed thereover and subsequently patterned using a mask to define the contact openings to the silicon surface.
[0053] Then the metallization layer is deposited and conventionally patterned using a mask. Then conventionally a final e.g. PSG or nitride passivation layer (not shown) is formed and masked to define the contact pads.
[0054] [0054]FIG. 10A illustrates a top side view of a portion of the PT-FET in accordance with one embodiment. In this case the cells are rectangular and isolated by the trenches, the small rectangles being the source regions 70 - 1 . . . , 70 -n. Hence the trenches are formed in a criss-cross pattern to define the rectangular cells. The mesa region 82 surrounding the cells is the termination region as in FIGS. 6 - 8 .
[0055] [0055]FIG. 10B shows alternatively a linear cell type arrangement where the trenches, while criss-crossing, have a different spacing in the left-right direction than they do in the vertical direction in the drawing. This represents a linear open-cell geometry with source regions 72 - 1 , 72 - 2 , . . . , 72 -n each isolated by the trenches and termination mesa region 82 .
[0056] [0056]FIG. 11 depicts the P-channel complement of the PT-FET of FIG. 3. This PT-FET has all conductivity types opposite to that of the PT-FET of FIG. 3. Shown are drain region 82 , body region 84 , source region 86 , and N+ doped gate electrodes 88 A, 88 B. Similarly, in the termination region (not shown) the conductivity types are complementary to those of FIG. 3. The dimensions of the PT-FET of FIG. 11 would be similar to those of FIG. 5, as is the doping concentration for each particular region within well known material constraints.
[0057] [0057]FIG. 12 shows another embodiment of an N-channel PT-FET which in most respects is identical to that of FIG. 3, but has the addition of a P+ doped body contact region 92 formed in an upper portion of the semiconductor structure. This allows, via a conventional source-body contact (not shown in FIG. 12), the shorting of the source region 44 to the body region 42 . This prevents bidirectional operation and so provides a device which operates with forward conductivity only.
[0058] The above description is illustrative and not limiting; further modifications will be apparent to one skilled in the art in light of this disclosure and are intended to fall within the scope of the appended claims.
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A trenched field effect transistor suitable especially for low voltage power applications provides low leakage blocking capability due to a gate controlled barrier region between the source region and drain region. Forward conduction occurs through an inversion region between the source region and drain region. Blocking is achieved by a gate controlled depletion barrier. Located between the source and drain regions is a fairly lightly doped body region. The gate electrode, located in a trench, extends through the source and body regions and in some cases into the upper portion of the drain region. The dopant type of the polysilicon gate electrode is the same type as that of the body region. The body region is a relatively thin and lightly doped epitaxial layer grown upon a highly doped low resistivity substrate of opposite conductivity type. In the blocking state the epitaxial body region is depleted due to applied drain-source voltage, hence a punch-through type condition occurs vertically. Lateral gate control increases the effective barrier to the majority carrier flow and reduces leakage current to acceptably low levels.
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CLAIM FOR PRIORITY
[0001] This application claims priority to Chinese Application No. 201610162688.2 filed on Mar. 21, 2016, which is fully incorporated by reference herein.
FIELD
[0002] The subject matter described herein relates to the technical field of mechanical design technologies, more specifically, it relates to a rotating shaft, a fan and an electronic device.
BACKGROUND
[0003] In order to more effectively cool servers, such as host servers, the revolving speed of cooling fans currently adopted is very high (e.g. over 20,000 rpm in some instances). As a result, the spindle of the fan produces a large amount of heat and cannot be cooled down in time, thus causing the fan to be prone to malfunction.
BRIEF SUMMARY
[0004] In summary, one aspect provides a rotating shaft, comprising: a spindle comprising an internal first channel; a wheel casing operatively coupled to the spindle, wherein the wheel casing comprises an internal second channel; and a bearing housing the spindle, comprising a third channel located between the bearing and the spindle; wherein the first channel, the second channel, and the third channel are located to form an enclosed annular channel configured to hold a substance.
[0005] Another aspect provides a fan, comprising: a plurality of fan blades; and a rotating shaft, wherein the rotating shaft comprises: a spindle comprising an internal first channel; a wheel casing operatively coupled to the spindle, wherein the wheel casing comprises an internal second channel; and a bearing housing the spindle, comprising a third channel located between the bearing and the spindle; wherein the first channel, the second channel, and the third channel are located to form an enclosed annular channel configured to hold a substance.
[0006] A further aspect provides an electronic device, comprising: a device body; a fan operatively coupled to the device body, wherein the fan comprises a plurality of fan blades and a rotating shaft; the rotating shaft comprising: a spindle comprising an internal first channel; a wheel casing operatively coupled to the spindle, wherein the wheel casing comprises an internal second channel; and a bearing housing the spindle, comprising a third channel located between the bearing and the spindle; wherein the first channel, the second channel, and the third channel are located to form an enclosed annular channel configured to hold a substance.
[0007] The foregoing is a summary and thus may contain simplifications, generalizations, and omissions of detail; consequently, those skilled in the art will appreciate that the summary is illustrative only and is not intended to be in any way limiting.
[0008] For a better understanding of the embodiments, together with other and further features and advantages thereof, reference is made to the following description, taken in conjunction with the accompanying drawings. The scope of the invention will be pointed out in the appended claims.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0009] FIG. 1 is a structural schematic diagram showing an exemplary rotating shaft.
[0010] FIG. 2 is a structural schematic diagram showing an exemplary rotating shaft.
[0011] FIG. 3 is a structural schematic diagram showing an exemplary rotating shaft.
[0012] FIG. 4A is a structural schematic diagram showing an exemplary structure.
[0013] FIG. 4B is a structural schematic diagram showing a partial view of the exemplary structure of FIG. 4A .
[0014] FIG. 4C is a structural schematic diagram showing a partial view of the exemplary structure of FIG. 4A .
[0015] FIG. 5 is a structural schematic diagram showing an exemplary structure.
[0016] FIG. 6A is a structural schematic diagram showing a partial view of an exemplary structure.
[0017] FIG. 6B is a structural schematic diagram showing an exemplary structure.
[0018] FIG. 7 is a structural schematic diagram showing the structure of an exemplary fan.
[0019] FIG. 8 is a structural schematic diagram showing the structure of an exemplary fan.
[0020] FIG. 9 is a structural schematic diagram showing the structure of an exemplary fan.
[0021] FIG. 10 is a structural schematic diagram showing the structure of an exemplary fan.
[0022] FIG. 11 is a structural schematic diagram showing the structure of an exemplary fan.
[0023] FIG. 12 is a structural schematic diagram showing the structure of an exemplary fan.
[0024] FIG. 13 is a structural schematic diagram showing the structure of an exemplary electronic device.
[0025] FIG. 14 is a structural schematic diagram showing a partial view of an exemplary structure.
DETAILED DESCRIPTION
[0026] It will be readily understood that the components of the embodiments, as generally described and illustrated in the figures herein, may be arranged and designed in a wide variety of different configurations in addition to the described example embodiments. Thus, the following more detailed description of the example embodiments, as represented in the figures, is not intended to limit the scope of the embodiments, as claimed, but is merely representative of example embodiments.
[0027] Reference throughout this specification to “one embodiment” or “an embodiment” (or the like) means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, the appearance of the phrases “in one embodiment” or “in an embodiment” or the like in various places throughout this specification are not necessarily all referring to the same embodiment.
[0028] Furthermore, the described features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are provided to give a thorough understanding of embodiments. One skilled in the relevant art will recognize, however, that the various embodiments can be practiced without one or more of the specific details, or with other methods, components, materials, et cetera. In other instances, well known structures, materials, or operations are not shown or described in detail to avoid obfuscation.
[0029] Referring now to FIG. 1 , the structure of a rotating shaft according to an embodiment is illustrated. In an embodiment, the rotating shaft can be the rotating shaft in various rotational structures, for instance, the rotating shaft in a fan. In an embodiment, the rotating shaft may include the following structures: a spindle 1 , a wheel casing 2 and a bearing 3 . The wheel casing 2 is connected to the spindle 1 and the spindle 1 is sleeved in the bearing 3 so that the spindle 1 can drive the wheel casing to rotate in the bearing 3 , as shown in FIG. 2 .
[0030] Referring now to FIG. 3 , in an embodiment, the spindle 1 is internally provided with a first channel 4 , the wheel casing 2 is internally provided with a second channel 5 , and a third channel 6 is formed between the bearing 3 and the spindle 1 . In an embodiment, the first channel 4 , the second channel 5 and the third channel 6 are connected to form an enclosed annular channel in which a first substance 7 can circularly flow in the annular channel to take away the heat emitted from the spindle 1 to the wheel casing, thereby cooling the spindle 1 .
[0031] In an embodiment, by arranging the first channel in the spindle of the rotating shaft, the second channel in wheel casing, and the third channel between the bearing and the spindle, the three channels can form an enclosed annular channel by connection. The first substance in this annular channel can flow inside or outside of the spindle to take away the heat of the spindle to the wheel casing, thus realizing timely cooling for the spindle and avoiding fan malfunction. In this way, the objective of the embodiment is achieved.
[0032] In an embodiment, in order to better cool the spindle 1 , a substance with higher heat dissipation performance, for instance, oil and the like, can be used as the first substance 7 in the annular channel. More specifically, a lubricating oil can be added into the annular channel to accelerate the flow and cooling, thus improving the cooling effect of the spindle 1 .
[0033] Referring now to FIGS. 4 (A-C), in an embodiment, in order to accelerate the flow velocity of the first substance 7 in the annular channel, a thread 8 with the first direction can be arranged on the outer side of the spindle 1 , as shown in FIG. 4A . The first direction is associated with the rotation direction of the spindle 1 so that the flow velocity of the first substance 7 in the annular channel can be greater than a preset first threshold value. The first threshold value may be understood as the flow velocity of the first substance 1 in the annular channel when there is no thread arranged on the outer side of the spindle 1 . Correspondingly, the meaning of the flow velocity being greater than the first threshold value is that the flow velocity of the first substance 7 when the thread 8 is arranged on the outer side of the spindle 1 is greater than that of the first substance 7 when no thread 8 is arranged on the outer side of the spindle 1 .
[0034] In an embodiment, when the rotation direction of the spindle 1 is the clockwise direction from the top view, as shown in FIG. 4B , the first direction can also be the direction which is high at left and low at right. Therefore, when the spindle 1 rotates clockwise at a high speed, the first substance in the thread 8 can be driven to accelerate the downward flow. In an embodiment, when the rotation direction of the spindle 1 is the counter-clockwise direction from the top view, as shown in FIG. 4C , the first direction can also be the direction which is low at left and high at right. Therefore, when the spindle 1 rotates counter-clockwise at a high speed, the first substance in the thread 8 can be driven to accelerate the upward flow.
[0035] Referring now to FIG. 5 , the structure of the rotating shaft according to an embodiment is illustrated. In an embodiment, the first channel 4 is connected with the second channel 5 through the first spindle hole 9 at the top of the spindle 1 . The first channel 4 is connected with the third channel 6 through the second spindle hole 10 at the bottom of the spindle 1 . The second channel 5 is connected with the third channel 6 through the third spindle hole 11 on the outer side of the spindle 1 . Thus, the first channel 4 , the second channel 5 and the third channel 6 can form an enclosed annular channel through the above three spindle holes, so that the first substance 7 can flow circularly in the annular channel, so as to cool the spindle 1 .
[0036] Referring now to FIGS. 6 (A-B), in an embodiment, as shown in FIG. 6A , the first channel 4 is a cylindrical channel. In an embodiment, as shown in FIG. 6B , the second channel 5 is an umbrella-shaped channel with an opening 12 . The third channel 6 is an annular channel with two openings 13 . Accordingly, the second channel 5 is connected with the opening (a) one end of the first channel 4 through the opening 12 (c 1 ) at the center of the umbrella-shaped channel. The second channel 5 is connected with an opening 13 (d 1 ) of the third channel 6 through the opening 12 (c 2 ) at both ends of the second channel 5 . The other opening 13 (d 2 ) of the third channel 6 is connected with the opening (b) at the other end of the first channel 4 . Thus, an annular channel, similar to a T-shaped structure, is formed between the first channel 4 , the second channel 5 and the third channel 6 , so that the first substance 7 can flow circularly in the annular channel, so as to cool the spindle 1 .
[0037] Referring now to FIG. 7 , the structure of a fan according to an embodiment is illustrated. In an embodiment, the fan refers to a fan for a device such as a laptop, desktop and the like, or other kinds of fans. In an embodiment, the fan may comprise the following structures: a rotating shaft 14 and fan blades 15 . The rotating shaft 14 may be composed of the following structures: a spindle 1 , a wheel casing 2 and a bearing 3 . The wheel casing 2 is connected to the spindle 1 , the spindle is sleeved in the bearing 3 so that the spindle 1 can drive the wheel casing to rotate in the bearing 3 . As shown in FIG. 8 , the fan blades 15 are arranged on both sides of the wheel casing 2 , and the spindle 1 rotates in the bearing 3 , so as to drive the wheel casing 2 and causing the fan blades 15 on the wheel casing 2 to rotate, thereby forming an air flow to cool the surroundings.
[0038] Furthermore, in an embodiment, the spindle 1 is internally provided with a first channel 4 , the wheel casing 2 is internally provided with a second channel 5 , and a third channel 6 is formed between the bearing 3 and the spindle 1 . Referring now to FIG. 9 , in an embodiment, the first channel 4 , the second channel 5 and the third channel 6 are connected to form an enclosed annular channel, wherein the first substance 7 can flow in the annular channel to take away the heat emitted from the spindle 1 to the wheel casing, thereby cooling the spindle 1 .
[0039] In an embodiment, by arranging the first channel in the spindle of the rotating shaft, the second channel in the wheel casing, and the third channel between the bearing and the spindle, the three channels can form an enclosed annular channel by connection. The first substance in the annular channel can flow inside or outside of the spindle to take away the heat of the spindle to the wheel casing, thereby cooling the spindle in time while the fan cools the surroundings, and avoiding fan malfunctions. In this way, the objective of the embodiment is achieved.
[0040] In an embodiment, in order to better cool the spindle 1 , the first substance 7 in the annular channel can be the substance with a higher cooling performance, for instance, oil and the like. More specifically, lubricating oil can be added into the annular channel to accelerate the flow and cooling, thereby improving the cooling effect of the spindle 1 .
[0041] In an embodiment, in order to accelerate the flow velocity of the first substance 7 in the annular channel, the thread 8 with the first direction can be arranged on the outer side of the spindle 1 , as shown in FIG. 10 . The first direction is associated with the rotation direction of the spindle 1 so that the flow velocity of the first substance 7 in the annular channel can be greater than a preset first threshold value. The preset first threshold value can be understood as the flow velocity of the first substance 1 in the annular channel when there is no thread arranged on the outer side of the spindle 1 . Accordingly, the meaning of the flow velocity being greater than the first threshold value is that the flow velocity of the first substance 7 when the thread 8 is arranged on the outer side of the spindle 1 is greater than that of the first substance 7 when there is no thread 8 arranged on the outer side of the spindle 1 .
[0042] In an embodiment, when the rotation direction of the spindle 1 is the clockwise direction from the top view, as shown in FIG. 4B , the first direction can also be the direction which is high at left and low at right. Therefore, when the spindle 1 rotates clockwise at a high speed, the first substance in the thread 8 can be driven to accelerate the downward flow. When the rotation direction of the spindle 1 is the counter-clockwise direction from the top view, as shown in FIG. 4C , the first direction can also be the direction which is low at left and high at right. Therefore, when the spindle 1 rotates counter-clockwise at a high speed, the first substance in the thread 8 can be driven to accelerate the upward flow.
[0043] Referring now to FIG. 11 , the structure of the rotating shaft according to an embodiment is illustrated. In an embodiment, the first channel 4 is connected with the second channel 5 through the first spindle hole 9 at the top of the spindle 1 . The first channel 4 is connected with the third channel 6 through the second spindle hole 10 at the bottom of the spindle 1 . The second channel 5 is connected with the third channel 6 through the third spindle hole 11 on the outer side of the spindle 1 , as shown in FIG. 5 . The first channel 4 , the second channel 5 and the third channel 6 form an enclosed annular channel through the above three spindle holes so that the first substance 7 can flow circularly in the annular channel, so as to cool the spindle 1 .
[0044] In an embodiment, the first channel 4 is a cylindrical channel, as shown in FIG. 6A , and the second channel 5 is an umbrella-shaped channel with an opening 12 , as shown in FIG. 12 . The third channel 6 is an annular channel with two openings 13 . The second channel is connected to the opening (a) at one end of the first channel 4 through the opening 12 (c 1 ) in the center of the umbrella-shaped channel. The second channel 5 is connected to an opening 13 (d 1 ) of the third channel 6 through openings 12 (c 2 ) at both ends, while the opening 13 (d 2 ) of the third channel 6 is connected to the opening (b) at the other end of the first channel 4 . Thus, an annular channel, similar to a T-shaped structure, is formed between the first channel 4 , the second channel 5 and the third channel 6 , so that the first substance 7 can flow circularly in the annular channel, so as to cool the spindle 1 .
[0045] Referring to FIG. 13 , the structure of an electronic device according to an embodiment is illustrated. The electronic device can comprise: a device body 16 and a fan 17 . In an embodiment, the fan 17 is connected to or close to the device body 16 , so that the fan 17 can cool the device body 16 . For example, as shown in FIG. 14 , the fan 17 may comprise: a rotating shaft 14 and fan blades 15 . The rotating shaft 14 may be composed of the following structures: a spindle 1 , a wheel casing 2 and a bearing 3 . The wheel casing 2 is connected to the spindle 1 , the spindle 1 is sleeved in the bearing 3 so that the spindle 1 can drive the wheel casing to rotate in the bearing 3 , as shown in FIG. 8 . The fan blades 15 are arranged one both sides of the wheel casing 2 , and the spindle 1 rotates in the bearing 3 , so as to drive the wheel casing 2 and causing the fan blades 15 on the wheel casing 2 to rotate, thereby forming an air flow to cool the device body 16 .
[0046] In an embodiment, the spindle 1 is internally provided with a first channel 4 , the wheel casing 2 is internally provided with a second channel 5 , and a third channel 6 is formed between the bearing 3 and the spindle 1 . In an embodiment, the first channel 4 , the second channel 5 and the third channel 6 are connected to form an enclosed annular channel, as shown in FIG. 9 , wherein the first substance 7 can flow circularly in the annular channel to take away the heat emitted from the spindle 1 to the wheel casing, thereby cooling the spindle 1 .
[0047] According to the above technical solution, by arranging the first channel in the spindle of the rotating shaft of the fan, the second channel in the wheel casing, and the third channel between the bearing and the spindle, the three channels can be connected to form an enclosed annular channel. The first substance in this annular channel can flow circularly inside or outside of the spindle to take away the heat of the spindle, thereby cooling the device body and the spindle of the fan in time, and avoiding fan malfunction. In this way, the objective of the embodiment is achieved.
[0048] As used herein, the singular “a” and “an” may be construed as including the plural “one or more” unless clearly indicated otherwise.
[0049] This disclosure has been presented for purposes of illustration and description but is not intended to be exhaustive or limiting. Many modifications and variations will be apparent to those of ordinary skill in the art. The example embodiments were chosen and described in order to explain principles and practical application, and to enable others of ordinary skill in the art to understand the disclosure for various embodiments with various modifications as are suited to the particular use contemplated.
[0050] Thus, although illustrative example embodiments have been described herein with reference to the accompanying figures, it is to be understood that this description is not limiting and that various other changes and modifications may be affected therein by one skilled in the art without departing from the scope or spirit of the disclosure.
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One embodiment provides rotating shaft, including: a spindle comprising an internal first channel; a wheel casing operatively coupled to the spindle, wherein the wheel casing comprises an internal second channel; and a bearing housing the spindle, comprising a third channel located between the bearing and the spindle; wherein the first channel, the second channel, and the third channel are located to form an enclosed annular channel configured to hold a substance. Other aspects are described and claimed.
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REFERENCE TO A RELATED APPLICATION
This a continuation in part application of my copending application Ser. No. 06-573,743, filed on Jan. 25, 1984, and now abandoned, which is a divisional patent application of my earlier patent application, Ser. No. 171,697 which was filed on July 24, 1980; benefit of which is claimed herewith. Application Ser. No. 171,697 is now abandoned.
FIELD OF THE INVENTION
This invention relates to control body arrangements in machines, where fluid flows through working chambers of the device. For example to hydrostatic pumps, motors, transmissions or pneumatic compressors, motors, engines and transmissions. More in detail the invention relates to those control body arrangements, where the control body has a control face on its front end to control the flow of fluid in relation to a rotary face, wherealong the control face of the control body is sealing. On the rear end or on medial portions of the controlbody there are seats provided with which the control body is entred into respective chambers in a portion of the housing of the machine. At least one chamber is a thrust chamber, which presses the controlbody towards the mentioned rotary face, whereby the sealing therealong is obtained and the control of the flow is effected.
The field of the invention thereby is a control body for axial flow of fluid to and from a rotor of a device, with the control body pressed by fluid pressure in a thrust chamber against the rotary face to seal therealong. And more in particular, the field of the invention is restricted to such control bodies, wherein at least one eccentric control body portion and an associated thrust chamber are provided.
DESCRIPTION OF THE PRIOR ART
It has been attempted long times ago and actually been done, to provide kidney-shaped thrust chambers and body-portions therein, to lead fluid to and from the kidney--shaped control ports in pumps and motors. While such arrangements would be the ideal solutions for proper and unrestricted flow of fluid combined with excellent axial alignment of the pressure centers involved, the fact is, that kidney-shaped chambers and body-portions are difficult to be machined. This is especially the case, because for the high pressure pumps and motors of the present time the seats must be extremely accurate and have extremely small clearances and close fits. Thereby it has become almost impossible to actually build and use the kidney-shaped chambers and control body portions.
The desire to replace the almost unmanagable production costs of kidney-shaped control body means has led to circular forms of chambers and portions, which are easy to be made and which can be machined with little cost to the required accuracy and fits.
One of the earliest and proper solutions of this kind is shown by Naylor and Fieldhouse of Vickers Armstrongs Ltd of London in West German Pat. No. 829,553 of 1951. It has two thrust chambers individually sealed and oppositionally diametrically located behind the control body. They act parallel to the axis of the rotor. The arrangement can provide properly located pressure centers. However, the patent does not discuss the requirement of proper location of the chambers in relation to pressure centers. Reviewing the patent with the present knowledge of the writer of this present patent application, the mentioned patent can provide a most excellent control body with proper functioning. However, the thrust chambers are required to be radially offset and thereby they are requiring a big radial space which is often not available in present day compact pumps and motors. Further, the said patent can be used only for relatively radially narrow ports, because for radially wide ports, the chambers would move out of the required axial alignment with the pressure centers of the control face.
It is also known to provide one or more centric thrust chambers to press the control body against the rotary face or a rotor against a stationary control face. For example from (West) German Pat. No. 824,295 of 1950 or from U.S. Pat. No. 3,951,044 of 1976 of myself. However, such centric thrust chambers can be used only, when the control body is so accurately guided, that it can not tilt. Because concentric chambers have a pressure center at the rotor-axis, while the control face of the control body has a pressure center distanced from the rotor-axis. Thus, the control face would be pressed locally different onto the rotary face, when a control body with a pressure center unequal to the pressure center of the control face would be used without guiding the control body mechanically so accurately, that local different forces are prevented.
It was then found in 1955 by Vetter and Borowka of the Saalmann Company of Velbert in (West) Germany and shown in their German Pat. No. 968,539, that the control body should have an eccentric shoulder in order to locate the pressure centers of the thrust chambers of a flow-direction reversible control body behind the pressure centers of the control face of the control body.
With the present discoveries of the writer of the present patent application, however, it must now become recognized, that the solution, which the said patent proposed, is an error. Because the patent utilized a thrust chamber behind the rear end of the control body and an eccentric chamber in addition. At such arrangement the pressure centers of the thrust chambers are closer to the axis of the rotor than the pressure centers of the control face portions. Thus, as the present writer now judges, the mentioned patent can not have provided a working control body because of its basic error of assumption of pressure centers at places and locations, where they do not actually exist.
A much more accurate solution, than the Vetter Borowka patent was then proposed during 1960 by Creighton in his U.S. Pat. No. 3,092,036. He aligned the pressure centers by the provision of blind pressure ports on the opposite half of the control face. Thereby, as the present writer today judges, the pressure centers of the control face moved closer to the rotor axis and could become equally distanced from the rotor-axis relatively to the existing pressure centers of the thrust chambers. However, that could have been done only for certain sizes and relationships of the control ports of the blind pockets. Thereby the application is restricted to limited radial size of the control ports. Further, the application of the blind pockets results in extension of seal faces and in the provision of additional leakage flows through the control face and the rotary face. The system also requires larger pressure chambers, than the elder Vetter-Borowka patent and thereby the thrust onto the bearings on the other end of the rotor increases. In short, while the Creighton patent brings a proper possibility for certain sizes of radial extension of the control ports, it increases the losses in the machine. And, in addition, the Creighton patent fails to bring proper mathematical formulas to show where the pressure centres are located and where the chambers have to be located properly.
All problems of the Vetter-Borowka and of the Creighton patents were overcome by my U.S. Pat. Nos. 3,831,496; 3,850,201; 3,889,577 and 3,960,060 of 1974 to 1976. These patents give accurate and extensive formulas and extensive teaching for actual building of the devices and arrangements. They provide an extensive basis and teaching for the technology involved, for accurate discovery and location of the pressure centers on different ends of the control body and they provide a proper knowledge for the actual designing and machining of the control bodies and the associated chambers.
SUMMARY OF THE INVENTION
After the accurate teaching for proper action was given in my mentioned earlier patents, the application of control bodies in actually built pumps, motors and transmissions increased. With the features obtained, the pumps and motors became smaller in size for a given power. That in turn created a desire to narrow the dimensions of the control bodies further. It became also a desire to extend shafts through the hollow control bodies. Thereby the relative radial extension of the respective control ports decreased. Also the pressures and speeds were increased in the pumps and motors.
It then occasionally happened, that the control bodies of my earlier patents bound in their seats. That was noticed, when the pumps or motors were disassembled years later after their production. Such sticking, when it occures, makes the control body to a non-moveable part, self-lockingly bound in the seats in the housing portion.
This occurance was a matter of concern to me for many years. Because it was not known, what the reason for this sticking was. The pressure centers on "gravity-centers" were very properly aligned. But still the control bodies or some of them, stuck sometimes.
It is now the discovery of this present patent application, that it is not enough to align the pressure centres properly as taught in my earlier patents. Because, there is another influence which can have a much greater effect onto the control body, than unproper location of the pressure-centers. This now discovered fact is, that, when the friction along the control face reaches just a few footpounds or kilogramcentimeters, the torque trends to revolve the control body slightly in its seats. When that happens, the relative to each other eccentric cylindrical faces of the seats then move along each other and partially towards each other under a very small angle of relative inclination.
It is just, as pressing a tapered cone of small angle of inclination into a complementary hollow seat. For example as done with the tools in lathe machines, drillspindles and the like.
Such tools with sharp cones are not used to slide, but they are used to fasten themself by self-lock under the increased forces which increase under the sharp inclination of the faces.
The same matter appears on the control bodies in their seats, when the control bodies are actually revolving under the torque by friction along the control face of the control body. At the sharp angles between the faces of the seats the force of the friction along the control face muliplies a hundred times, a thousand times or even ten thousand times, because the sharpness of the relative angles between the faces in the seats of the control body is much, much sharper than in the mentioned drillspindle-cones.
A very slight rotation, of for example, one degree or a fraction thereof, can already force the sticking of the control body. The control body can then not any more loosen itself. It remains bound until it becomes unlocked by rotation in the opposite direction.
It is therefore the object and aim of this invention, to present the sticking of the control body by preventing the destructive trend of rotation of the control body.
The object and aim of the invention is obtained by two basic principles:
(a) to dimension the controlbody in such a style, that the eccentricity in combination with reduction of friction along the control face restricts the tendency of the control body to revolve slightly and then to stick; or,
(b) when the a principle does not assure the desired aim, to provide an arresting means of mechanical nature for the prevention of eccessive rotation of the control body.
There are a plurality of means, which are applied either single or in combination, to obtain the aim and object of the invention.
Still another solution is at least partially to utilize the equations of my mentioned earlier patents to a highest possible degree of accurateness. For example to build the control bodies and chambers in such perfectness, that their sizes and locations meet the conditions of the equations with at least 90 percent accuracy.
One discovery of the invention thereby is, that the sticking of the control body can become prevented by a high degree of correspondance of the actual building with the equations in combination with proper eccentricities to narrow or reduce the tendency to rotate and to stick.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 shows a portion of the basic control face of a control body.
FIG. 2 shows a control body in its seats with extremely enlarged clearances of the seats.
FIG. 3 is an explanatory Figure to explain the sticking of the control body under rotation along the arrow of FIG. 1.
FIG. 4 explains the mathematical values of a control face.
FIG. 5 gives a universally valid diagram for the pressure centers "Gc" of the control face of a control body.
FIG. 6 is a longitudinal sectional view through an embodiment of a control body of the invention.
FIG. 7 is a cross-sectional view through FIG. 6 along the line VII--VII.
FIG. 8 is a cross-sectional view through FIG. 6 along the line VIII--VIII.
FIG. 9 is a longitudinal sectional view through an other embodiment of a control body of the invention.
FIG. 10 is a cross-sectional view through FIG. 9 along the line X--X.
FIG. 11 is a view onto FIG. 9 from XI.
FIG. 12 is a longitudinal sectional view through a third embodiment of a control body of the invention.
FIG. 13 is a cross-sectional view through FIG. 12 along the line XIII--XIII.
FIG. 14 is a cross-sectional view through FIG. 12 along the line XIV--XIV.
FIG. 15 is a cross-sectional view through a control face portion of a fourth embodiment of a control body of the invention.
FIG. 16 is a sectional view through FIG. 15 along the line XVI--XVI.
FIG. 17 is a sectional view through FIG. 15 along the line XVII--XVII.
FIG. 18 is a cross-sectional view through a control face portion of a fourth embodiment of a control body of the invention.
FIG. 19 is a cross-sectional view through a control face portion of a fifth embodiment of a control body of the invention.
FIG. 20 is a sectional view through FIG. 19 along the arrowed line in FIG. 19.
FIG. 21 is a sectional view through FIG. 19 along the arrowed line XXI--XXI.
FIG. 22 is a longitudinal view through the sixth embodiment of a control body.
FIG. 23 is a longitudinal sectional view through the seventh embodiment of a control body of the invention.
FIG. 24 is a longitudinal sectional view through an axial piston device of the invention.
FIG. 15 is a portion of FIG. 24 showing another flow direction.
FIG. 26 is an alternative of a control body to FIG. 24 and thereby a longitudinal sectional view through the eighth embodiment of a control body of the invention;
FIG. 27 is a longitudinal sectional view through a preferred embodiment of an arresting means of the invention.
FIGS. 28-A to 28-F show schematics with mathematical explanations.
FIGS. 29-A to 29-E show also schematics with explanations.
FIG. 30 is a longitudinal sectional view through an arranment with some members shown from the outside.
FIG. 31 is a view from the right of FIG. 30 onto FIG. 30, and:
FIG. 32 is a longitudinal sectional view through a controlbody in an enlarged scale with some actual meawritten in the Figure.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Control body 1 in FIGS. 1 to 3 has a front portion 3, a medial portion 4 and a rear portion 5. The front of the control body has the control face 2 which is also visible in FIG. 2. Control body 1 is inserted into the housing portion 9 and forms therein the chambers 6 and 7 and the seats 203,204,205. The seats are drawn in FIG. 1 with very big enlarged clearances 203 to 205. Actually the clearances are only about a few hundredth of a millimeter in size.
FIGS. 1 to 3 are explanatory Figures and are supplied to illustrate the action which is discovered by the present invention.
When the rotary face of the rotor runs over the control face 2 in the direction of the arrow in FIG. 1 the control body follows this rotation along the direction of the arrow in FIG. 1. At least one of the portions 3,4,5 of the control body is eccentric relatively to at least one of the other mentioned portions. For example, portions 3 and 5 may be centric, but portion 4 eccentric to the axis of the rotor and to the axis of the other portions 3 and 5.
Attention is now requested to FIG. 3. The housing 9 has formed the centric seat face(s) 210 with radius 211 around the concentric axis 216 and the eccentric seat face 206 with radius 215 around eccentric axis 217. Under the rotary motion by following the arrow in FIG. 1, one of the outer faces of a respective control body portion becomes close to one of the seat faces in the housing 9. The control body then slides along it and displaces itself, until finally the former centric axis of the control body 1 moves from axispoint 216 to 218 and the eccentric axis moves from former location 217 to dislocation 209. The eccentric portion 4 of the control body then touches with its shoulder of radius 208 around dislocated axis 209 the inner face 206 under a very small angle of relative inclination between the faces. The formerly centric portion touches also under a very sharp angle of relative inclination between the faces with the shoulder of radius 213 around the dislocated axis 218 against the inner face 210 of the seat in the housing 9. With the big enlarged clearances shown in the Figures, the angles of inclination between the faces appear to be roughly one or a few degrees in the Figures, because the clearances are shown larger in the Figures than they actually are and enlarged clearances show enlarged angles of pivotal movement. The sticking (binding) appears in lines 207 and 219. The element numeral 208 is the radius of the seat of the control body around the dislocated axis 209. The element numeral 210 is the seat face of the respective seat of the housing portion and face 212 is the respective seat face of the respective shoulder of the control body. The mentioned radii are those of the respective seat faces of the control body.
In actuality, however, the angles of inclination between the faces are very small, for example, only a fraction of a degree. At actual calculation of the dislocations described, usual "sin" and "cos" function tables can not be used any more. Specific electric calculators are required for the actual calculation, because the "sin" and "cos" values appear at the sixth or seventh to eighth place behind the point after the zero.
Under these very stiff angles of inclinations between the faces described, the force with which the control body seat faces press into the seat faces of the housing multiplies extremely at lines 207 and 219 and may reach forces of tons even when the force on the arrow of FIG. 1 is actually only a few pounds. Under these forces the control body 1 sticks very hard between the lines 207 and 219 in FIG. 3.
This discovery of the sticking, as described, is the basic discovery of the present invention.
The further action of the invention is, to provide means, which prevent the rotation of the control body in the direction of the arrow in FIG. 1. When the rotation is prevented, the sticking of the control body is also prevented, because the sticking of the control body can actually appear only, when it revolves in the direction of the arrow of FIG. 1.
While the rotation of the control body is shown to be about 60 degrees in FIG. 3, because of the enlarged clearances 203 to 205, the actual angle of rotation until the sticking takes place, is only around one degree, less than one degree or a few degrees. In most actually built devices the sticking takes place, when the control body revolves about one half or two thirds of a degree. The angle of rotation until sticking occurs, depends on the size of the eccentricity and on the size of the radial clearances 203 to 205. The eccentricity is shown by "e" in FIG. 2. If the clearances 203 to 205 in FIG. 3 are actually 100 times smaller than they are drawn in FIG. 3, then the degrees of the pivotal movement (turn) would also be 100 times smaller, namely 60 degrees devided by 100=0.6 degrees at which the control body would bind. It should be noted that the control body does not weld in the seats of the housing but can be softened in the housing by a soft hammer blow in the direction opposed to the direction of the pivotal movement at which the control body bound.
Another discovery of the present invention is demonstrated in FIGS. 4 and 5. The calculation of the gravity center of a control face is given by exact equations in my mentioned patents. The calculation was, however, a matter of time consumption, because the equations were not simple and for every single control body the pressure center distance "Gc" from the axis of the rotor was to be calculated.
This present invention now discovers, that a generally useable diagram with a single curve can be developed, when the distance "Gc" of the pressure center of the control face from the axis of the rotor becomes written over the value of the relation:
ΔR/Rpc.
I call this curve "Gc rel" and the formula for the simple calculation of the actual "Gc" value of the control body is given in FIG. 5. The curve for "Gc rel" is also given in FIG. 5. FIG. 4 gives the actual equation for a symmetric control face of 180 degrees halves, which is the basis for the novel curve "Gcrel" of FIG. 5. FIG. 4 also demonstrates the actual locations of the pressure field's outer radius Ro and the pressure field's inner radius Ri of the control face as well as the medial radius "Rpc" of the pressure field of the control face.
Thus, the actual value of "Gc" of each control face 2 of a control body 1 can now be simply found at hand of FIGS. 4 and 5 for every actual design of a control body.
FIGS. 6 to 8 illustrate a most simple novel control body of the invention, wherein the control body 11 has only two seats 13 and 14. At least one of the seats is eccentric to the axis of the rotor, but actually often both seats are eccentric to the axis of the rotor. The Figures illustrate the first eccentricity 15 which forms with radius 17 the first seat 13 and a second eccentricity 16 which forms with radius 18 the second seat 14. Shown are also the control ports 9 and 10.
It was discribed in the opening part of this specification, that the Saalmann-Vetter Borowka reference can not have equalities of the pressure centers "Gc" and "gc" because the end of the control body 11 was subjected to a pressure chamber. Consequently, the control body of FIGS. 6 to 8 could also not have equal "Gc" and "gc" values and could therefore not properly function or work.
To prevent such unequalness of the "Gc" and "gc" centers, the present invention now disvcovers, that the equalness of the "Gc" and "gc" locations can be established very economically and with almost no costs, thereby, that a medial recess 19 becomes provided in the control face 2 and that it becomes communicated to the end of the control body, for example by a bore 20. Thereby a communication is established between the rear pressure thrust chamber on the rear end of the control body 11 and the medial recess 19. The medial recess 19 can be circular and centric for simplicity of machining. Support portions 21 may be applied in the medial recess 19 and form bearing faces in order to increase the bearing capacity of the control face 12 relative to the rotary face of the rotor.
The size of the medial recess 19 must be calculated and the pressure center of it must become incorporated in the actual "Gc" calculation of the control face 2. The pressure centers "gc" of the chambers behind the seat 14 and between seats 13 and 14 must be given such diameters and eccentricities 15 and 16, that their pressure centers "gci" and "gco" of chambers behind 13 and between 13 and 14 are with at least ninety percent of accuracy behind the pressure centers "Gci" and "Gco" of the control face. Meaning, that the distances "Gco" and "gco" as well as the distances "Gci" and "gci" from the axis of the rotor must be at least of ninety percent in accuracy with the equations of this patent application.
The embodiment of the invention of these Figures is not only most simple in machining, but it also prevents the pressure center unequalnesses of the mentioned Vetter Brorowka patent and it prevents the doubled leakage flows of the Creighton patent. It also is more simple in machining than the Creighton control body of his patent. Thus, the control body of this embodiment of the invention has also the feature of an increased reliability and economy of operation. A space 22 can be provided in the rear eccentric portion to make an assembly of respective parts of the motor or pump thereinto possible or to make the control body of reduced weight for application in airborne devices.
Also possible is, to set a recess or bore 23 for the reception of an arresting means, when the eccentricities 15 and 16 would be too small to prevent alone by themselves the rotation and sticking of the control body 11. The pressure chamber between the seats 13 and 14 is in practice often called "the outer chamber", while the pressure chamber rearwards of seat 14 is called "the inner chamber" because it lays radially inwards of the axial projection of the mentioned outer chamber. The control ports 9 and 10, however, are equally radially distanced from the concentric axis of the rotor. Therefore, there can not be an inner and an outer control port. Consequently, the control port 10, which is communicated to the outer chamber, is named "the first control port" while the control port 9, which is communicated to the mentioned inner chamber and to the medial recess 19, is named "the second control port". The pressure areas around the respective control ports are called "pressure zones" and they define in their centers the respective pressure centers "Gco" and "Gci" whereby the indices "o" and "i" define the relation and communication to the mentioned outer or inner chamber.
The next embodiment of the invention is demonstrated in FIGS. 9 to 11. The feature of this embodiment of a control body of the invention is, that all eccentric shoulders are spared. That makes the control body simple in machining and of little production costs, because all seats 33,34 and 35 of this control body are centric to the axis of the rotor. To make this possible for equalness of "Gc" and "gc" values, the control face 32 is provided with balancing recesses 36 and 37. These are so dimensioned, that they have equal "Gc" distances as the diametrically located control ports. For example the "Gc"-value of the 37 balance recess area is equal in size to the control port area 9 and the balance recess area area 36 is equal in its "Gc"-value to that of the control port area 10. But the "Gc" directions of the balancing recess areas are oppositionally directed to the "Gc" directions of the control port areas relatively to the axis of the rotor.
Balancing recess 36 is communicated for example by channel or bore 39 to the thrust chamber between seats 35 and 34. The balancing recess 37 is communicated by passage 40 to the thrust chamber between seats 33 and 34. The control port 9 extends into the thrust chamber between seats 33 and 34, while the control port 10 extends into the thrust chamber between seats 35 and 34. A medial recess 38 may be provided through or into the control body and may interrupt the medial portion of the control face 32 of control body 31.
When the seats are all centric, as described, there must be arresting provisions 23 provided in order to prevent rotation of the control body. These are in this case, however, simple matters, because the control body with all seats centric, can not stick as those with relatively to each other eccentric seats. The arresting means 23 can therefore be in this embodiment simple bores with pins engaging them with relatively large clearances and without an overly high degree of accuracy.
Instead of making all seats centric it is also possible to make them eccentric, when the ports 9-10 are radially large, for example. The balancing recesses 36 and 37 may then be narrower, bringing smaller "Gc"-values and thereby demanding eccentric seats partially for the equalization of the "Gc"- and "gc"-values. The bore 38 can then be provided in order to make it possible to extend a shaft through the control body 31 and thereby out of an end of the pump or motor wherein the control body is applied.
The other embodiment of the invention is demonstrated in FIGS. 12 to 14. It has the control ports 9 and 10 in control face 42 and may also have the medial bore 48. The specifity of this embodiment is, that the control body has second control ports 46 and 47. Control port 46 communicates to control port 9 and control port 47 is communicated to control port 10. Thereby it becomes possible to operate multiple chamber groups of a respective pump or motor. For example one working space group by control ports 9 and 10 and another by control ports 46 and 47. The consequence thereof however is, that the seat 44 must be eccentric and relatively large eccentric to the axis of the rotor. Whether the other seats 43 and 45 are centric or eccentric depends on the actuall "gc"-values, because the condition "Gc-s equal to gc-s" must be obeyed with at least 90 percent accuracy to the equations of this specification. Otherwise the control body would stick unless the rotation of the control body would be prevented by a very accurate arresting means 49. The actual measure-relation of a bore 48 in relation to the other measures may be different to the embodiment of FIGS. 9 to 10. Ports 9 and 46 are communicated to the thrust chamber between seats 43 and 44, while the control ports 10 and 47 are communicated to the thrust chamber between seats 44 and 45.
Regarding the embodiment of FIGS. 6 to 9 it should be recognized, that the area of the control face which is connected to control port 9 is bigger in cross-sectional area than that which is connected to control port 10. Consequently, the thrust chamber between seats 13 and 14 has a smaller cross-sectional area than the thrust chamber behind seat 14. It is thereby an important and novel characteristic of the embodiment of FIGS. 6 to 9 of the invention, that the circular thrust chamber behind seat 14 has a bigger cross-sectional area, than the sickel-shaped thrust chamber between seats 13 and 14.
To "stick" or to "bind" are terms used to define that the ability to move is lost.
In the embodiments of FIGS. 15 to 17 several possibilities of communications to chambers are shown. And also demonstrated is, that recesses 57 and 58 might be utilized as control ports or as balancing recesses upon desire.
The arrangements of these Figures are basically similar to FIGS. 9 to 11, but FIGS. 15 to 17 are drawn in a larger scale. And further additional possibilities are demonstrated. FIG. 15 shows the ports 9 and 10 as well as the recesses 55,57,58,56. The lines in ports 9 and 10 demonstrate, that there can be ribs in the ports for the obtainment of radial strength. The lines in recesses 55,56,57,58 in FIG. 15 however shall demonstrate, that there could be different communication channels, such as in FIG. 16 or as in FIG. 17 or also as in some of the later Figures.
FIG. 16 shows, that control port 9 extends into the thrust chamber between seats 53 and 54. The Figure also shows, that control port 10 can obtain a passage of considerable cross-sectional area to extend into the thrust chamber provided between seats 35 and 54. The recesses 55 and 56 in FIG. 16 are balancing recesses similar to those of FIGS. 9 to 11 and they can be respectively communicated by channels which are not shown in FIG. 16. For example recess 55 communicates with the chamber between seats 35 and 54. Recess 56 communicates with the thrust chamber between seats 53 and 54.
What FIG. 17 separatedly demonstrates, is, that the recesses 55,56 of FIG. 16 can be used as control ports, when they are provided with passages of suitable cross-sectional area as shown in FIG. 17. Control port 57 extends then to the thrust chamber between seats 53 and 54. Control port 58 extends then into the thrust chamber between seats 35 and 54. Thus, the control face 62 has inner and outer recesses 9,10,55,56 or 57,58 whereof the latter can be used or built as control ports as in FIG. 17. The connection to the thrust chambers could also be vice versa, if so desired.
FIG. 15 in combination with FIGS. 16 and 17 shall also demonstrate, that the control body could have control ports 9 and diametric control port 58 be communicated to the thrust chamber between seats 53 and 54. And control port 10 with the diametric control port 57 to the thrust chamber between seats 35 and 54. Or the passages could be set vice versa. The actual communication of this kind is however not shown in FIGS. 16 and 17, but will be understood when FIGS. 24 and 25 are viewed regarding the passages through the control body. For example the control body of FIG. 24 shows a passage from control port 10 into the chamber between seats 35 and 54. It also shows a passage from port 57 to the thrust chamber between seats 35 and 54. And FIG. 25 shows in its control body a passage from port 58 to the thrust chamber between seats 53 and 54, when the respective passages would be provided in the control body of FIGS. 15 to 17.
The central bore 38 and seat 35 serve principially the same purposes as in FIGS. 9 to 11.
FIGS. 15 to 16 are drawn in an actual scale, where the "Gc"-values of the inner outcuts 55,56 or 57,58 are equal to the "Gc"-values of the outer recesses or control ports 9 and 10. But the "Gc"-values of the inner chambers are diametrically oppositionally directed respective to the outer recesses or outcuts. Thereby the sum of the respective co-operating and co-communicated recesses, ports and chambers are summarizing up to zero and so do the "gc"-values of the thrust chambers. The reduction of the scale of the drawing in the expected patent will not very drastically change the relationship of the values discussed.
When the relative radial extensions and locations are changed, the summarization of the "Gc"-values may change and an eccentricity may then be needed for one or more of the seats 35,54 and/or 53. Thus, the use of the control body and of the communications therethrough depends largely on the actual desire, whereby however, the rules for equalness of "Gc"- and "gc"-values must be obeyed. When centric thrust chambers are used, the arrester against rotation must be set, as explained at hand of FIGS. 9 to 11. The arresting means is however not shown in FIGS. 15 to 17, because it is already understood from FIGS. 9 to 11.
FIG. 18 demonstrates, that an optimum of cross-sectional area of control ports can be obtained, by eliminating the medial bore 38 and separating the inner recesses or outcuts or ports from each other by a narrow sealing land 59. The condition "gc=Gc" must be obeyed again. The communication of the inner and outer recesses or ports must be done crosswise, as in the other Figures of similar relation. Thus, spaces with "A" must communicate together and spaces defined by "B" must communicate together in FIG. 18. Spaces with sign A must be communicated to one of the chambers and those with "B" to the other of the thrust chambers on the rear portion of the control body. The Figure is drawn as a sectional view parallel to the control face of the control body.
The embodiment of the invention which is demonstrated in FIGS. 19 to 21 has four circular shoulders with seats 65 to 68 on control body 61. Each circular seat 65 to 68 is formed with an equal radius around a center, whereby the centre of each seat is located in the pressure center "Gc" of the control face of the control body. Thereby the center--axes of the seats 65 to 68 are located eccentrically of the axis of the rotor. While there are four such seats, there can be any desired multiples of two seats provided with in each case two diametrically relatively to the axis of the rotor located seats are forming a seat pair of opposite or different pressure. The provision of four seats 65 to 68 as shown in the Figures is however the most practical one, because thereby a most compact design is obtained which can easily be used to extend into central outcuts of the respective rotor. The Figures are shown in a scale of true relationships, where the "Gc"- and "gc"-values are equal and the thrust chambers 63,64 etc. of the seats 65 to 68 are suitably dimensioned to force the control body 61 strongly enough but not too strong against the rotary face of the respective rotor. Each seat or shoulder 65 to 68 extends into a respective thrust chamber like 63 or 64 in FIG. 21 in the housing portion 60 of the device. It should be noted, that the control ports 9 and 10 do not extend straightly through the control body 61 but only into it and they are closed towards the rear end of the control body 61 with the exception of passages which extend into and through the respective seats 65 and 68.
Control port 9 thus extends into its twin seats 65 and 67 of the respective shoulders 65 and 67 which extend into the respective thrust chamber and seal therein by seats 65 and 67. Control port 10 extends into its twin shoulders and seats 66 and 68. These shoulders 66 and 68 are again extended into a respective thrust chamber in housing portion 60 and are sealed therein by seats 66 and 68.
It is seen from the Figures, that the thrust chambers are simple cylinders with inner faces and the shoulders are simple cylinders with outer faces fitting into the inner faces of the thrust chambers by their seats 65 to 68. These provisons can be simply machined and the assembly prevents itself from rotation. The arrangement can not stick. The provision of a plurality, but preferredly of a pair of such seats 65 to 68 to a single control port as done by this embodiment of the invention, provides a clear equalness of the "gc"- and "Gc"-values and it gives a comfortable design of compactness and small radial extension, wherein the seats 65 to 68 only very slightly extend over the outer diameter of the control face.
A different style of production of the control body arrangement of FIGS. 19 to 21 becomes possible by FIGS. 22 and, or, 23. These Figures demonstrate, that, instead of making the shoulders 65 to 68 integral with the control body 61 it would also be possible to machine bores 70 to 71 into control body 72. The bores 70 to 71 which may be a plurality thereof, for example four such bores, end into the respective control port 9 or 10. Axially aligned with the respective bores are then pipe portions 74, 75 equal in number to the number of bores 70,71. These pipe portions are extending into the bores 70 to 71 and are sealing therein. They are fastened in the Figures in the respective housing portion 76 or 77. The pipes thereby seal the bores 70 to 71 and they are also keeping the control body 72 or 73 in its proper position and prevent it from rotation. The axes of pipes and bores 70,71,74,75 are again located in the pressure center "Gc" of the control face 2. So, as in FIGS. 19 to 21. Passages 78 and 79 are the exit- and entrance-passages of the device and are located as in the other Figures in the respective housing portion 76 or 77.
When the control body 73 of FIG. 23 is used only for a single direction of flow, the low pressure area of control port 10 may not need a sealed passage of flow, when fluid is permitted in the interior space of the motor or pump, wherein the arrangement of FIG. 23 is applied. It is then satisfactory to set only two bores 70 or a plurality of bores 70 and of holding pipes 74. They will keep the control body 73 in its proper place, will prevent it from rotation, will exclude sticking and dislocation, will passe the high pressure fluid to or from the working spaces in the rotor and seal the passage of high pressure fluid effectively. They will also provide the proper thrust in the direction towards the rotor and will obey the rule: "gc equal to Gc". In this figure as well as in all the other Figures the control body must be axially moveable to complete the thrust against the rotary face of the rotor. Seal seats for plastic seals, like O-rings, may be provided in the respective shoulders or pipe portions of the figures. They are shown in the Figure by referentials 80.
The control body 81 in FIG. 24 demonstrates the possibility to control a plurality of fluid flows through a device and to let the flows flow in opposite directions on the respective half or substantial half of the machine.
Rotor 95 is revolvably borne in housing 87. The bearing of the rotor 95 is done by medial shaft 91 and its shoulder 94. The rotor 95 seats on radial seats of shaft 91 and the front face of the rotor 95 is partially embraced by shoulder 94 of shaft 91. Shaft 91 is borne in the rear bearing seat 119 of shaft 91 and of housing 87 and it is borne in the front of housing 87 by radial bearing means 101 whereof the shaft itself may constitute a bearing portion as it may also do in rear bearing 119. A thrust bearing 100 is formed for example in the front portion of housing 87 to carry thereon the axial thrust of shaft 9. The shoulder 94 of shaft 91 then carries the axial thrust in forward direction, which might be excerted onto the rotor 95. Bearing 100 and/or 101 may be fluid bearings and may be supplied with fluid under pressure through passage 98 in shaft 91 and through communication passages 99. Respective fluid under pressure may be led into passage 98 by a respective pressure source or by communication to a respective thrust chamber 85 or 86.
The radial cross-sectional areas of thrust chambers 85 and 86 behind control body 81 are slightly--for example by factor "fb"--larger than the cross-sectional areas of the respective pressure zones along control face 82 on the front end of control body 81. Thereby control body 81 is pressed against the rotor 95 in forward direction, whereby the control face 82 touches the rear end face of rotor 95, seals therealong and presses rotor 95 forward against the shoulder 94 of shaft 91 and thereby shaft 91 against the front--axial bearing 100. Axial bearing 100 carries the mentioned and applied axial load of thrust chambers 85 or 86 respectively; however minus the load of the pistons 92 and 93 in the cylinders 83 and 84 of rotor 95. Because, the axial load of pistons 93 is borne over connecting rods 96, the rotary seat plate 160, thrust bearings 113 and inclineable plate 114 the axial load of pistons 92 is borne over connecting rods 96, rotary seat plate 103, bearings 106, 107 and inclineable plate 161. Thus, the load of fluid pressure in the cylinders 83, 84 is not carried by medial shaft 91.
The embodiment of the invention of this Figure has a plurality of working chamber groups in rotor 95. The drawing is set into such condition, that the different working space groups 83, 84 are operating in opposite directions in the same substantial half of the control zone. One working space or cylinder group is represented by referentials 83 and the other by referentials 84. When fluid flows along the arrows on the left half of the drawing into cylinders 83 it flows out in the opposite direction out of cylinders 84 on the left side of the drawing. Fluid flows then into cylinders 84 on the right side of the drawing and out of cylinders 83 on the right side of the drawing, as the arrows indicate. The directions of flows can be reversed, as it is illustrated in FIG. 25.
FIG. 25 is just the bottom portion of FIG. 24, however, with the other passage connection of control body 81.
In FIG. 24 at the situation as drawn, fluid enters through connection or entrance port 90 into the outer thrust chamber 85. From there the fluid flows through thrust chamber 85 into passages 123 and 120 of control body 81 and through control ports 9 and 58 of control body 81 into cylinders 83 and 84 of rotor 95. The fluid leaves the cylinders 83 and 84 through control ports 10 and 57 of control body 81 and flows then through passages 121 and 122 of control body 81 into and through the inner thrust chamber 86 and out from there through connection port or exit port 89.
The reversed direction of the flows is shown in FIG. 25. There port 89 serves as entrance port and port 90 serves as exit port. The fluid flows through entrance port 89, inner thrust chamber 86, passages 121, 122; control ports 10, 57 into the respective cylinders of cylinder groups 83 and 84 and out thereof through control ports 9, 58, passages 120, 123, outer chamber 85 to and out of now exit ports 90.
The reversal of the direction of the flows may become effected either by counter--rotational direction of rotor 95 or by opposite inclinations of the inclineable control discs or control plates 114, 161.
The radial sizes of control face 82, rotor 95, cylinders 83 and 84 as well as that of the medial outcut in rotor 95 and in control face 82 and control body 81 are drawn in a proper scale, at which the chamber groups 83 and 84 are forming in the respective pressure zones of the control face 82 and around control ports 9, 57, 68, 10 equal cross-sectional pressure areas on opposite sides of the axis of rotor 95, shaft 91 and control face 82 and control body 81. Consequentely the thrust chambers 85 and 86 on the respective rear portions of control body 81 are provided with equal cross-sectional areas. The rear seat 162 restricts the inner thrust chamber 86 radially inwardly.
At those actual designs of the invention, where the pressure centers "Gc" are equally but diametrically oppositionally distanced from the said axis of the rotor, the thrust chambers 85 and 86 are centrically located relatively to each other and also to the axis of the rotor. Where the sum of the "Gc"-values is not zero, the thrust chambers 85 and/or 86 are provided eccentrically either one of them or both and relatively to the axis of the rotor or also to each other.
Equal cross-sectional areas of the double control port pair system of the here discussed Figures are possible as long as the radial distance through the radially outer pressure zone remains smaller than one third of the medial radius of the outer pressure zone. Or, in other words, "delta R/Rpci" of the outer zone must remain smaller than 0.33.
Instead of having one flow of fluid flowing through the plural working cylinder groups of FIG. 24 it is also possible to let two separated flows of fluid flow through it. That is demonstrated by way of an example of a respective embodiment in FIG. 26. The rear portion of the device, which may be a radial or axial piston device, pump or motor, has four separated thrust chambers and four separated passages through the respective control body 131. One separated flow flows through cylinder group 83 and the other separated flow flows through cylinder group 84. When the "gc"-values of the thrust chambers are equal to the respective "Gc"-values of the control face 132, the pressures in the plural flows can be different.
The outer cylinder group flow flows from entrance port 137 through thrust chamber 133, passage 146, control port 9 into the respective intaking cylinders 83 of group 83 and leaves the respective discharging cylinders 83 of group 83 through control port 10, passage 148, thrust chamber 134 and exit port 140.
The inner cylinder group flow flows from entrance port 139 through thrust chamber 136, passage 149, control port 58 into the respective intaking cylinders 84 of cylinder group 84 and leave the respective expelling cylinders 84 of cylinder group 84 through control port 57, passage 147, thrust chamber 135 and exit port 138. The directions of the flows may be reversed. Instead of extending the entrance and exit ports to right and left as shown in FIG. 26, the may extend in oppositional direction, axially or in an inclined direction.
When the "gc"-values are equal to the "Gc"-values in all control-zones and thrust chambers, the directions of the flows are unristricted. That means, that both flows can then be independently controlled and reversed.
The control body 131 forms respective shoulders and seats. For example, as FIG. 26 shows, the front seat 141; the seat 142 between thrust chambers 133 and 134; seat 143 between thrust chambers 134 and 135; seat 144 between thrust chambers 135 and 136 and the rear seat 145. The rear chamber 128 is commonly communicated to a space under no or under low pressure.
The seats have to seal the respective thrust chambers and they must be located and dimensioned with at least 90 percent of accuracy relatively to the equations of this patent application.
FIG. 24 also demonstrates by example, how the control of the delivery quantity of the plural flows can be controlled. The heads 104 of connecting rods 96 are borne in seats of the rotary seat plate 103. The heads 111 of connecting rods 96 are borne in the other rotary seat plate 160 . The mentioned connecting rod heads may be kept in the respective seats by holding means or holding plates 110 and 112 respectively. The inner heads of the connecting rods are set into the pistons 92 or 93 respectively.
Rotary seat plate 103 is driven by shaft 91 and rotary seat plate 160 is driven by rotary seat plate 103. For that purpose spherical gears or splains 108 are formed between shaft portion 97 and the inner rotary seat plate 103. Respective sphaerical gear or splain means 109 are formed between the inner rotary plate 103 and the outer rotary seat plate 160. Thereby the shaft 91, the rotor 95, the inner rotary seat plate 103 and the outer rotary seat plate 160 are revolved in unison.
The inner rotary seat plate 103 is borne in axial thrust- and radial bearing 107-106 of the inner inclineable adjustment plate 161. The bearing may be a mechanical bearing or, as shown in the Figure, a hydrostatic bearing with sealed fluid pressure pockets 106, 107. Fluid under pressure may be led into pockets 106, 107 out from the respective cylinders 83 through bores in the connecting rods 96 and through respective passages 163, 164 in parts 103 and 161. Bearing 107 may be an axial thrust bearing, while bearing 106 may be a radial bearing. They could become replaced by a single bearing, when set normal to the direction of thrusts of the connecting rods 96.
The outer rotary seat plate 160 is radially and axially borne in mechanical bearings 113 on the outer inclineable adjustment plate 114.
The inner and outer adjustment plates 114 and 161 may have a common controller for adjustment of their inclination. For example an oppositionally acting common controller for opposite increase or decrease of the inclination of the plates 114 and 161. The common controller could also adjust them in equal inclination direction, if so desired. In such case, the plates 114 and 161 may also be replaced by a common single inclination adjustment plate.
In FIG. 24 it is however indicated, that there also could be independend controllers 116 and 115 be provided to the respective inclination adjustment plates 114 and 161. Supports 117 with spherical inner guide and bearing faces 118 might become provided behind the respective inclination adjustment plates 114, 161, when so desired.
The degrees of inclinations of the plates 160 and 114 or 103 and 161 define the stroke of the pistons 92 and 93 and thereby the quantity of the flows through the device.
FIG. 27 shows a preferred example of an arresting means to prevent rotation of a control body, which would otherwise stick, as described in this patent application.
The respective control body 151 is provided with a recess 152, which might be a recess 23 of FIGS. 6 to 11. In the housing portion 150 a pin 157 is inserted. Pin 157 has a centric portion with axis 155 and an eccentric front portion 153 of a smaller diameter around eccentric axis 156. The front portion 153 is engaged into recess 152 in control body 151. To prevent the rotation of control body 151, which would lead to the described sticking of the control body, the pin 157 is revolved in housing 150 until the outer wall of the eccentric portion 153 touches against the respective portion of the inner wall of recess 152. When this touching is properly reached, the arresting pin 157 is blocked from further rotation by a stopper pin 154 in housing 150, which enters into arresting pin 157 and keeps it in the set position.
The eccentric portion 153 is provided on arresting pin 157, because the accuracy of setting of control body 151 is very high. The restriction of the rotation of control body 151 should be less than one degree. In such case a common drill of a bore into the control body might not accurately enough have the same axis as the bore of the setting of the pin into the housing. The application of the eccentric portion on arresting pin 157 and the revolving of pin 157 and its fixing by stopper pin 154 serves to asure the proper arresting of the control body by the adjustment of slightly unequal axes by the rotation of the eccentric portion 153 in the slightly wider recess or bore 152 in control body 151.
The mathematical equations, which must be obeyed in this patent application and which are known from my mentioned earlier patents, are: ##EQU1## with: A HPmb =cross-sectional area of the thrust chamber;
Ro=outer radius of pressure zone around control port;
Ri=inner radius of pressure zone around control port.
See hereto FIG. 4 and use the radii of the high-pressure equivalent zones.
G=(180+2 gamma)/360. See hereto FIG. 4.
For high speed devices gamma becomes zero, because gamma appears gradually changing between minus and plus, when a rotor passage runs over the closing arc of the control body. Thus, in most cases, Gamma sums up to zero and G becomes 0.50.
fb=Balancing factor. It is commonly 1.02 to 1.08 and defines which which force the thrust chamber shall press the control body against the end face of the rotor or against the rotary slide face. ##EQU2## wherein the "R" values are explained above and seen in FIG. 4. fG becomses 0.6369 when gamma is zero (symmetric, 180 degree control face). Otherwise ##EQU3## with α in arch values.
And: ##EQU4## wherein the "r"-values are the outer and inner seat-radii of the respective thrust chambers and "θ" is an angular intervall of calculation. A good formular for calculation of the pressure center "gc" of the respective thrust chamber at hand of the above equation (3) is given for example in my japanese patent application publication No. 92 604 of 1974 or my German Pat. No. 23 00 639. "e" is the eccentricity of the shoulder. See FIG. 9.
At the present time it is however more convenient to spare the time of calculation in the formulars, which requires about 4 hours, to find one "gc"-value with an electric pocket calculator. It is therefore now recommended to use a small programmable calculator, for example Casio FX-502 P. This little computer is nowadays available for about a hundred dollars.
With the following symbols: M=Memory in and R=memory recalled with the diget thereafter the number of the memory, the casio can be programmed in mode 2 as follows: ##EQU5## When the above program was typed in the Writing mode 2=WRT into for example programm Po, the calculator has to be returned to the operation mode 1=RUN.
The following constants have to be put into the following memories:
______________________________________arc θ = o,174 into M11; 8 arc θ = 1,392 into M12;Piγ θ/540 = 0,0582 into 1/4 = o,25 into M14;M13;17,4 into M5; 36 into M10; and 3,1416 into MF.______________________________________
Therein the value "17.4" is an improvement over the earlier used "18" and nears a more perfect solution, because the radius runs not excactly through the medial intervall "θ".
With the above programm, developed by the inventor, there are remaining only thre variables, namely: "e", ro, and ri or rm.
They are to be typed into the following memories: "e" into M2; "ro" into M3, and: "rm" into M4; or: "e" into M2; "rm" into M3; and: "ri" into M4.
The computer is now programmed to calculate the Ba values of intervalls of 10 degrees θ.
Operate the calculation as follows: calculate the intervalls with alpha=0, 10, 20, 30, 40, 50, 60, 70, 80, 100, 110, 120, 130, 140, 150, 160, 170, and 180.
By typing: Ac, Po, alpha Min1, Exe.
Use "0" as the first alpha. Memorize, that the "Ba" values of alpha "0" and "180" must be halved, before becoming memorized in memory M9. The others are not to be halved.
After the "0" was used for alpha and Ac, Po, 0, Min 1, Exe was typed, the computer uses about 25 seconds to calculate the "Ba-Value" of alpha=zero. Type, after the result has appeared, type: %, 2,=; to half the result.
Type the result into memory 9 by typing: Min 9.
Continue the calculation by using the next alpha, which is: 10.
Type: Ac, Po, 10, Min 1, Exe. When result came, type: +,R9,=,Min,9. The first two results have now been summarized in memory 9. Continue the next value of alpha.
Type: Ac, Po, 20, Min, 1, Exe, -- wait, type: +,R9,=,Min,9.
After the last result, that of 180 alpha, has appeared and was halfed as it was done by alpha zero, continue to type: EXE and the sum of the "Ba" values appears, Note it down.
Type again: EXE and the integral medial value of "Ba" appears. Note it down.
Type again: EXE and the cross-sectional area of the thrust chamber appears. Note it down.
Type again: Exe and the integral value of K1 appears. Note it down.
Thereafter divide by normal calculation the value of medial Ba through K1. The values are between the last four noted results. The result of this final calculation is: "gc" or "gc+e".
By the above proposed calculation methode, the time of calculating one "gc" pressure center of a thrust chamber reduces from approximately four hours to less than ten minutes.
When the "gc-value" is not equal to the "Gc-value", try a number of other eccentricities "e" until a diagramm can be written with "gc" over "e" and the "e"-place be found, where "gc" would be allright. Re-calculate the so found "e"-value to be sure, that the "gc"-value is now correct.
That the thrust chambers can be made circular by summarizing the "Gc"-values of the control face to zero, can not in all dimensions be done. Often in praxis, a rather large cross-sectional area of the passages and ports is desired. In those cases it is not all times possible to summarize the "Gc"-values of the control face to zero and then at least one of the thrust chambers must become placed eccentrically with "gc=Gc". Thereby the "gc"-values are becoming often very small and that results then in small eccentricities "e", which proves how important the arresting of the control body of the invention can become.
For two thrust chambers, whereof one is located on the end of the control body and is circular, the other surrounds is as sickel-shaped with one point of the circles meeting, which means, that the maximally possible eccentricity "e" is applied and, when both chambers are of equal cross-sectional area, the following linear values apply, whereby sometimes calculations of sophisticated nature can be spared: ##EQU6## What this present patent application considers to be known in the former art, is:
A control arrangement in a device which takes in and expells fluid through passages and ports and through working spaces located in a rotor which is revolvably borne in a housing, at least one rotary slide face is formend on a portion of the rotor, at least one pressurized fluid containing thrust chamber formed in a portion of the housing and communicated to at least one of the passages, a control body inserted at least partially into the thrust-chamber with a rear shoulder towards the interior of the thrust chamber and forming a non-rotary control face on the front end of the control body which is interrupted by control ports to control the flow of the fluid to and from the working spaces and through the rotary slide face while the pressurized fluid in the respective thrust chamber presses the control body towards the rotor to seal with the control face along the rotary slide face when the rotary slide face slides and revolves over the control face of the control body, wherein the respective thrust chamber forms a pressure centre axially behind the respective pressure center of the respective control portion of the control face;
and what is considered to be one of the basic provisions of the invention, is, that means are provided on the control body to prevent sticking of the control body under forces appearing along the control face during slide of the rotary slide face over the control face;
while details of the provisions of the invention are, for example demonstrated as follows:
that said means is a relationship between the pressure center "gc" of the respective thrust chamber, the eccentricity "e" of an eccentric shoulder of said control body, a low balance factor "fb" for slightness of higher thrust in said chamber compared to the oppositionally directed thrust along said control face and an accuracy of at least ninety percent of the said pressure center "gc" and the pressure center "Gc" of the respective control face portion, whereby said rotation and sticking of said control body is prevented by the thereby obtained minimizing of friction on said control face and said eccentricity is able to maintain the proper alignement of said control body to prevent it from rotation within its seats and thereby to eliminate the sticking of the control body by clamping together of faces under extremely small angles of relative inclination.
Or, as explained at hand of FIGS. 6 to 11;
that said means is at least one arresting pin in at least one arresting recess, one of said pin and of said recess in said housing and the other of said pin and said recess in said control body and said pin engaged in said recess to prevent rotation of said control body relatively to said housing beyond the clearance between said pin and the respective portion of the wall of said recess, while said clearance is smaller than the angle of rotation of said control body in said housing at which the respective portions of the outer faces of the control body would touch the respective portions of the inner faces of the seats in said housing.
Or, as is explained by FIGS. 12 to 14 and the description thereof;
that a pin is fastened in the housing and engaged in a recesss in said control body to prevent rotation of a control body which has exclusively centric portions.
And, as explained at hand of FIGS. 19 to 23;
that said means is the provision of at least two portions engaging at least into two recesses, said provision centers around the pressure center "Gc" of the said control face and one of said portions and of said recesses is located in said housing and the other of said portions and of said recesses is located in said control body.
And, as explained in FIGS. 6 to 8 and the description thereof:
that means are provided on the control body to prevent sticking of the control body under forces appearing along the control face during slide of the rotary slide face over the control face, and
while said control face is provided with a medial recess, said control body has exclusively one front seat and one rear seat in said housing, at least said rear seat is eccentric relatively to the axis of said rotor, a first chamber is formed between said seats and a second chamber is formed on the rear of said rear seat, said second chamber is communicated to said medial recess, said chambers have different cross-sectional areas, each of said chambers communicates separatedly with the respective control port of said control face and the cross sectional area of said second chamber covers the area of the control zone around the aligned control port plus the area of the said medial recess and its seal while the cross-sectional area of said first chamber covers the area of the control zone around the other control port of said control ports.
and, that said control zone around said other control port forms a usual pressure center "Gco", but the said respective control zone forms a more radially inwardly relatively to the other "Gc" located pressure center "Gci" by the combination of said respective control zone and said medial recess, while the pressure center "gco" of said first chamber is located axially kof said "Gco"--center, but the pressure center "gci" of said second chamber is located axially of said more inwardly located pressure center "Gci" of said control face.
And, as explained in FIGS. 9 to 11 or 15 to 17 nd the description thereof,
that said control face forms substantially the usual basic first pressure control half and second pressure half with said halfs forming seal faces around their respective control ports and with substantially closed control archs between said substantial halves for the pre-compression and expansion or sudden pressure change in the respective working spaces, which are controlled by said halfs of said control face but wherein at least one additional recess is provided in addition to the respective control port in the respective half and said recess communicates with the control port in the first pressure half when it is located in the second pressure half and communicates with the control port of the second pressure half when it is located in the first pressure half, wherein said at least one recess forms a recess-pressure center "Gcr" while the respective pressure center "Gc" of the communicated control half forms in combination with said center "Gcr" a combined and relatively to said center "Gc" radially inwardly displaced summarized pressure center "Gcs" and the respective pressurized chamber which is communicated to the respective control port provides with a cross sectional area substantially able to cover the fluid pressure areas of said respective control port and of said respective recess and which forms a pressure center "gcs" substantially axially of said summarized pressure center "Gcs" of said control face, and wherein said substantially is of such a high degree of accuracy, that it forms said means to prevent said sticking of said control body.
And, that said accuracy exceeds ninety percent of the equalness to the equations (1) to (4) of this specification.
And, that in combination with the specifities which are shown in FIGS. 9 to 17, a central bore extends through said control body and through said control face and into a room of substantial low pressure.
Or, as explained at hand of FIGS. 9 to 26;
that said at least one additional recess consits of a first recess and a second recess, said first recess is located in said second pressure half but communicated with the control port in said first pressure half; said second recess is located in said first pressure half but communicated with the control port of the second pressure half to form by said locations and said communications first and second summarized control face pressure centers "Gco's" and "Gci's";
wherein said at least one pressureized fluid containing thrust chamber consists of at least two separated thrust chambers whereof one is the outer chamber and the other is the inner chamber; wherein each of said chambers substantially covers by a respective balancing factor "fb" the area of the the respective summarized area "Gc's" of the control face on the other end of the control body;
and, wherein the pressure center "gco" of the said outer thrust chamber is located axially of the respective summarized pressure center "Gco's" of the control face and the pressure center "gci" of the said inner thrust chamber is located axially of the respective summarized pressure center "Gci's" of the control face on the other end of the control body.
or, that said outer and inner chambers are eccentrically relatively to each other and to the axis of said rotor.
Or, as demonstrated in FIG. 18,
that said first and second recesses are separated from each other by a relatively narrow sealing land of parallel ends and said recesses have auter walls bordering sealing lands around said recesses which border on the respective control ports and are substantially parallel to the inner walls of said control ports in order to obtain a maximum of utilization of the said control face.
Or, as shown in one or more of the Figures, for example, as seen in FIGS. 9 to 11,
that said summarizations obtain the sum of zero, whereby said summarized pressure centers "Gcos" and "Gcis" are becoming the distance zero from the axis of the rotor and thereby becoming equal to the axis of the rotor and as the result of the condition of axiality of centers "gco" and gci" between the centers "Gco" and "gci" the said inner chambers and outer chambers of said at least one thrust chamber are becoming centric chambers with pressure centers "gco" and "gci" equal to zero.
And, as FIGS. 9 to 11 show,
that said recesses of said at least one recess are provided with separated passages which extend through said control body from the respective recess into the respective chamber of said thrust chambers.
Or, as seen in FIGS. 15 to 17 and 24 to 26,
that said passages have cross-sectional areas of sufficient size to facilitate the passage of a flow of fluid through said passages and whereby said recesses thereby are transformed to additional third and fourth control ports for control of a second flow of fluid through said control body into and out of at least one second group of working chamber spaces in said rotor of said device.
Which Figures also show,
that said control ports form flow control pairs with an entrance- and an exit-control port to each flow of said flows.
Or, that two of said entrance ports are located in one of said substantial halves and two of said exit ports are located in the other of said substantial halves of said control port areas of said control face.
And, as FIG. 26 demonstrates,
that each of said substantial halves of control zones of said control face contains at least one separated entrance control port and at least one separated exit control port and at least two of said passages through said control body incline radially outwardly or inwardly within said control body to communicate with a respective chamber of said chambers radially of the respective control port.
In FIGS. 28-A to 29-E more mathematical schematics with equations are shown as additional possibilities to calculate the control body arrangement exactly. These Figures illustrate the newer discoveries of the applicant for partially simplified calculation systems of the control body arrangement. The basic explanation is given at FIG. 28-A. FIG. 28-A is thereby the summary of the detailed explanations of the other portions of FIGS. 28-A to 29-E. Based on this consideration of FIG. 28-A, the area which rvolves around an axis leads finally to the simple equations belonging FIGS. 28-A to 29-E to find the pressure centers of the respective rear shoulder faces or of the pressure chambers (thrust chambers) of the control body arrangement of the invention. It might be understood that the results of these new equations to FIGS. 28-A to 28-E are the same as that of the earlier discussed calculations. The systems of FIGS. 28-A to 29-E are applicable, however, only under the geometrical conditions which are shown in these Figures while the earlier discussed systems of calculation are applicable generally for all geometrical conditions of the control body arrangements of the invention.
The consequence of FIG. 28-A is, that, if the volume of a body which revolves around an axis is known, the distance of the area center of the body from the axis where around the body revolves, can become calculated by dividing the volume "J" by "2 pi F" with pi=3.14 and F=the area. Thus, the following appears:
S=J/2piF
with "S"=the distance of the area center from the axis where around the body revolves and, consequently, S would correspond to the value "gc" of the invention.
FIGS. 30 and 31 illustrate an arrangement to determine the angle of pivotal movement at which the control body would bind in the housing portion of the devcie. As it is described in this specification, there is presently no exact system to calculate the angle of pivotal movement at which the control body would or might bind. In a co pending application a rough estimation for such a calculation is given but the estimation is not very accurate since at the pivotal movement of the control body the concentric axis will not remain concentric but depart from its concentric location. The control body may not only pivot slightly but may also move up, down, to the left or right in a limited extent. Thus, an exact calculation of the condition under which the control body would bind in the housing, is not possible, at least not at the present time. If a control body arrangement of the invention shall be properly designed, the condition under which the control body might or would bind, must, however, be known. It is therefore recommended to built a testing arrangement of FIGS. 30 to 31 and use it to determine by test the angle at which the control body binds. For that purpose a lever 211 becomes mounted in radial direction onto the housing portion of the arrangement. A lever 212 becomes mounted in radial direction onto the control body. The mounting may be accomplished by holding means 214 and 215. The levers are set radially aligned with each other at the concentric location of the control body in the housing portion. The lever 212 is then pivoted by hand in the direction of 213 until a further pivotal movement becomes impossible because the control body binds in the housing portion. The angle 213 is then measured. This is the angle of pivotal movement at which the control body binds in the housing portion. Once this angle 213 is measured the permissable clearances for the arresting means of the invention can become calculated and a precise and reliable control body arrangement of the invention can become designed and be built. After the measuring of the angle 213 has been done, the lever 212 can become moved back into its original zero position. The binding of the control body in the housing is then removed and the control body can be taken out of its housing portion. The fasteners 214 and 215 can then be taken off and the arrangement can be used. It is of interest that for every actual design of measures of a control body the here described measurement of the binding angle of the arrangement has to be done only one time. Since therefrom the angle at which the respective control body will bind, has become determined, every control body arrangement of the same dimensions will be free from binding in the housing portion, if the results of the measurement and its consequences for the actual design and building are obeyed.
FIG. 32 illustrates a control body of FIGS. 1 to 3 in a longitudinal sectional view in a very dratsically enlarged scale. In the Figure some measures are disclosed to illustrate the actual dimension as an example. The speciality of this Figure is that plastically deformable seal rings 246 are inserted in seal ring seats 247 of the control body.
The seal rings 246 are here made of a plastic material which exceeds 70 shore scale "A" hardness but remains below 96 shore scale "A" hardness. This specific hardness of the seal rings 246 provide a certain holding and concentering effect for the control body 1 in its surrounding housing portion 9. By applying the mentioned seal rings in the mentioned seal seats the seal rings provide a prevention of pivotal movement and of binding of the control body if the machining and design is very accurate and if the balancing factor "fb" is 1.04 plus/minus 0.3. and if the pressure in the device remains less than 300 Kilograms per centimeter squared, the greatest diameter of the control body remains less than 60 millimeter and the revolution of the rotor of the device is less than 3000 revolutions per minute. The referential numbers of FIGS. 30 to 32 which are here not discussed, are known from the description of other Figures of the present patent application. More details of the preferred embodiment are described in the appended claims. The claims therefore are considered to be a portion of the description of the preferred embodiments.
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A control arrangement to control the flow of fluid through pumps, motors, transmission, engines has an eccentric shoulder assembled into a respective thrust chamber in a portion of the housing to be pressed against the rotary seal face of the rotor of the device. Such arrangements are known from some of my earlier patents and have served satisfactorily, but with the desire to improve the pressures further, it has been found, that arrangements are required to prevent the control body from slight rotation, under which it otherwise would stick. The arrangement provides the means to prevent the rotation and sticking by defining a relationship between eccentricities and gravity centers in order to reduce the tendency to stick. Pins and pins with eccentric and adjustable portions are also used to prevent the tendency to stick and so are pluralities of eccentrically arranged individual thrust chambers and control body portions. A specific feature of the embodiment which is claimed consists in a control body with only two seats for reversible directions of flow of fluid and for high performance of operation with low friction an small leakage.
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FIELD OF THE INVENTION
The present invention relates to vibrating conveyors, and more particularly, to a vibratory conveyor of the flat stroke design, capable of conveying in both the forward and reverse flow direction.
BACKGROUND OF THE INVENTION
Two-way flat stroke vibratory conveyors or feeders have substantial applications in a variety of fields. One typical application is in foundry operations wherein, for example, foundry castings may be delivered to a conveyor energized to feed the castings to one end or the other, depending upon where it is desired to locate the castings. Another typical application is in the bulk operations of granular materials wherein, for example, sugar, sand, stone, flour, cement, and various other chemical compounds may be delivered to one end or the other in the same way. Additionally, the conveyors may also move combinations of these object, granular and powder materials.
A conventional two-way flat stroke conveyor made according to the prior-art will typically include a motor powered drive system that includes four drive shafts having pairs of eccentric counterweight wheels connected via an elaborate belt connection. This drive is coupled to an elongated bed with an upwardly facing, generally horizontal conveying or feeding surface terminating at opposite ends. In operation the two sets of eccentric counterweight wheels are driven such that the wheels in each set rotate in opposite direction and the two sets are 90° out of phase relative to one another. When the motor powers the drives, a cyclic vibratory force is produced and the output displacement is transferred to the bed to create material flow. If one were to plot the sum of the stroke versus stroke angle of the sets of eccentric counterweight wheels, the result would be a skewed or biased sine wave in the direction of material flow. By reversing the rotation of the system, the skewed sine wave is reversed and the material flow is reversed.
This prior art conveyor poses a number of problems, the greatest of which is the complexity of the drive on what is essentially a brute force system. In other words, as the drive consists of four shafts with pairs of eccentric counterweight wheels, and the wheels, bearings and shafts must be large to transfer the forces, the result is a complex belt drive system with great maintenance and alignment difficulties.
U.S. Pat. No. 5,934,446 to Thomson (incorporated herein by reference) attempts to address these problems with a vibratory conveyor that includes a generally horizontal, elongated conveying surface connected to a base by generally vertically arranged, resilient slats. A drive is mounted to the surface and includes two rotary eccentric shafts coupled in series and set 90° out of phase for vibrating the surface in a generally horizontal direction by imparting a cyclic vibrating force in the form of a skewed sine wave. In other words, the drive, through the connecting drive slats, imparts a horizontal force to the trough, causing it to vibrate in the horizontal direction.
Essentially, the conveyor in the Thomson patent is tuned, through the reactor slats, to approximately 7% above the primary shaft rpm. This design, as such, takes advantage of the sub-resonant natural frequency and reduces the forces to the drive bearings as well as reducing the motor size requirements as compared to the prior art. In other words, the primary horizontal eccentric force and stroke is amplified and the lessor secondary eccentric wheel force is transmitted in a brute force manner, resulting in a smaller skewing stroke component. However, the disadvantage of the Thomson patent remains its drive complexity and space limitation with respect to both manufacture and maintenance costs.
Accordingly, it is a general object of the present invention to provide a new and improved flat stroke bi-directional conveyor.
Another general object of the present invention is to overcome those deficiencies of the flat stroke conveyors of the prior art.
It is a more specific object of the present invention to provide an improved flat stroke bi-directional conveyor which utilizes the skewed sine wave principle to transfer force to the conveying bed.
It is another object of the present invention to provide an improved conveyor which utilizes less and smaller component parts, as compared to current practice, thereby greatly reducing manufacture and maintenance costs.
SUMMARY OF THE INVENTION
The invention is generally directed to a bi-directional vibratory conveyor having a trough with an upper conveying surface for transferring energy to convey material along the surface. The drive assembly includes a drive shaft with a primary counterweight and a driven sheave, a motor shaft with a secondary counterweight and a driver sheave, a timing belt connecting the sheaves and a motor having a reversible output connected to the motor shaft for causing a direction of rotation that produces both horizontal and vertical energy components.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the present invention which are believed to be novel, are set forth with particularity in the appended claims. The invention, together with the further objects and advantages thereof, may best be understood by reference to the following description taken in conjunction with the accompanying drawings, in the several figures of which like reference numerals identifying like elements, and in which:
FIG. 1 is a side elevation view of a flat stroke bi-directional conveyor made according to the principles of the present invention with certain parts omitted for clarity purposes.
FIG. 2 is a cross-sectional top plan view of the bi-directional conveyor made according to the principles of the present invention taken along lines 2 — 2 of FIG. 1 .
FIG. 3 is a cross-sectional frontal view of the bi-directional conveyor made according to the principles of the present invention taken along lines 3 — 3 of FIG. 1 .
FIG. 4 is a cross-sectional rear view of the bi-directional conveyor made according to the principles of the present invention taken along lines 4 — 4 of FIG. 1 .
FIG. 5 is a cross-sectional rear view of the bi-directional conveyor made according to the principles of the present invention taken along lines 5 — 5 of FIG. 1 .
FIG. 6 is a graph plotting stroke versus stroke angle of the primary and secondary counterweights as well as the combined sum of the two frequencies showing the skewed sinusoidal stroke.
FIG. 7 is a graph of the combined sum of the two frequencies of FIG. 6 when the motor rotation is reversed.
FIG. 8 is a depiction of the eccentric counterweight wheel positions every 90° of counter-clockwise rotation of the secondary wheels.
FIG. 9 is a depiction of the eccentric counterweight wheel positions every 90° of clockwise rotation of the secondary wheels.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
An exemplary embodiment of a flat stroke bi-directional conveyor or feeder is illustrated in the drawings and will be described herein as a conveyor, it is understood that the terms conveyor and feeder are synonymous for purposes of the present application. Referring now to the drawings, and particularly to FIG. 1 , a conveyor 10 constructed in accordance with the invention is seen to basically include a base 12 , which may be mounted on the underlying terrain as, for example, the floor of a building, a table structure or the like. Supported about the base 12 is a generally horizontal, elongated, trough 14 having opposed ends 16 and 18 , as well as an upper conveying surface 20 . The trough 14 is supported about the base 12 by a series of vertically arrayed, vertical resiliency members 22 , for example a rocker leg and coil spring combination, or, preferably vertical leaf spring slats of conventional construction that are secured to both the underside of the trough 14 and to the base 12 at spaced locations via fabricated structural brackets 24 and fabricated brackets 26 respectively.
The drive assembly, FIG. 2 , consists of a structural drive fabricated horizontal rectangular box 28 and is preferably opened at the top and bottom. Two flange bearings 30 are mounted on each longitudinal side holding a lateral drive shaft 32 which in turn supports two primary eccentric counterweights 34 . A preferably totally enclosed and non-ventilated heavy duty reversible shaker motor 36 is bolted at one end of the drive box 28 so that the motor shaft 38 is lateral and horizontal to the elongated trough 14 . Two secondary eccentric counterweights 40 are mounted on the motor shaft 38 . The two primary eccentric counterweights 32 are driven by a synchronous timing belt 42 and driver and driven sprocket system are respectively longitudinally aligned whereby the driver sheave 44 is mounted on the motor shaft 38 and the driven sheave 46 is mounted on the primary drive shaft 32 . The drive assembly is attached to the trough 14 with a horizontal resiliency member 48 , preferably a leaf spring slat connected to the drive at the opposite end of the drive motor 36 and attached to a trough drive bracket 50 that is in turn connected to the trough 14 . Lastly, a spring 52 is connected to the bottom side of the drive and at the opposite end to the base 12 .
Thus far, FIGS. 1 and 2 have been shown and described to give the overall look and general structure of the principle components of the present invention. Turning now to the cross-sectional views of FIGS. 3-5 , the functional aspects of the principle components of the present invention are shown and described. Referring to FIG. 3 , the front of the drive assembly is shown with respect to its position above the base 12 and beneath the trough 14 as supported by the spring 52 . Within the drive box 28 is the shaker motor 36 which drives motor shaft 38 . The two secondary eccentric counterweights 40 rotate about the shaft 38 upon the motor 36 generating rotational power to the shaft 38 . Also, coupled to and rotating with the motor shaft 38 is the driver sheave 44 . The driver sheave 44 in turn rotates the driven sheave 46 through timing belt 42 . In the preferred embodiment, the driven sheave 46 is preferably twice the diameter of the driver sheave 44 , thereby causing the primary eccentric counterweights 34 to rotate at half the speed of the secondary eccentric counterweights 40 . Although, multiple combinations may provide the desired results, these speeds of rotation are preferably 300 r.p.m. and 600 r.p.m. respectively.
Referring now to FIG. 4 , the rear of the drive assembly is shown with respect to its positions above the base 12 and beneath the trough 14 as supported by the spring 52 . The previously discussed rotation of the driven sheave 46 in turn rotates the lateral drive shaft 32 , which is supported within the drive box 28 by flange bearings 30 , thereby causing the two primary eccentric counterweights 34 to rotate about the drive shaft 32 . The primary eccentric counterweights 34 and the secondary eccentric counterweights 40 are timed so that the primary eccentric counterweights 34 are horizontal when the secondary eccentric counterweights 40 are vertical i.e. lag the primary eccentric counterweights by 90°. The spring 52 illustrated in FIGS. 1-4 as being connected to the bottom side of the drive assembly and the opposite end connected to the base 12 serves a dual purpose. First, the spring 52 is sized to isolate and help support the drive assembly from the base 12 and accordingly nearly eliminates the vertically induced forces transmitted to the ground. In other words, the forces of the wheels not in line with the trough stroke (infra) are absorbed via this spring. Second, the spring 52 supports the drive assembly weight in order to relieve pre-loading the horizontal leaf spring slat 48 .
Finally, FIG. 5 illustrates the coupling of the base 12 and the trough 14 through the leaf spring slats 22 that are connected thereto by fabricated structural brackets 24 and fabricated brackets 26 respectively. These leaf spring slats 22 are sized so that the total spring rate sets the single mass natural frequency of the elongated trough 14 mass at preferably about seven percent (7%) over the primary running frequency. Furthermore, the leaf spring slats 22 are positioned vertically with respect to the base 12 and trough 14 so that the direction of the vibratory motion is horizontal and parallel to the elongated trough 14 .
With the general structure and function of the component parts shown and described with respect to FIGS. 1-5 , FIGS. 6-9 are now discussed as they relate to the general operation of the present invention. During operation and when the motor 36 is turned on to rotate the motor shaft 38 in a counter-clockwise manner, the secondary eccentric counterweights 40 and the primary eccentric counterweights 34 transfer energy through the horizontal leaf spring slat 48 , the trough drive bracket 50 , and ultimately the trough 14 in the form of a modified sinusoidal skewed stroke pattern as shown in FIG. 6 . This stroke pattern has been termed a “skewed sine wave” in that the slope of one side of each wave is shallower than the slope of the other side of the wave. Thus, if the stroke pattern illustrated by FIG. 6 is being applied to the components in the manner illustrated in FIGS. 1-5 , movement of the trough 14 to the right, that is toward the end 18 , will be relatively slow while the return movement toward the other end 16 will be relatively fast. In this case, conveying will be to the right because the slow movement to the right will allow the material being conveyed to frictionally engage and be advanced in that direction by the conveying surface 20 of the trough 14 . On the other hand, the fact that the return is so rapid, and the fact that the material still contains momentum energy from the rightward stroke will result in little or no reverse movement during the return stroke. The net result will be conveying of the material to the right.
When the operation is as in FIG. 7 , the opposite will occur. By reversing the motor rotation, the sinusoidal skewed stroke is biased to the left and the material flow is reversed to the left. As above, but stated differently, the stroke is skewed, now to the left, so that the trough movement to the left takes approximately twice the time which results in a low enough acceleration force, to promote material conveyance during the portion of the cycle as the return movement to the right does. The result is a biased impulse to the left causing material on the trough to be conveyed to the left.
As shown and described, it is the transfer of energy of the counterweights to the trough that produces the material flow. The present invention provides this forward material flow because the eccentric counterweight wheels are aligned such that the secondary wheels lag the primary wheels by 90° when the primary wheels are in line with the line of action of the trough stroke. The 90° offset fixed eccentric counterweight wheels are further capable of producing reverse material flow because the offset run in the opposite direction changes from a lagging profile to a leading profile resulting in reversing the skewed sinusoidal stroke.
This lagging/leading 90° offset is best illustrated with respect to FIGS. 8 and 9 respectively. FIG. 8 shows a step-wise representation 54 of the relative positions of the primary 34 and secondary 40 eccentric counterweights for every 90° counter-clockwise rotation 56 of the secondary eccentric counterweights 40 . The phase illustration 58 to the right of the nine-step series 54 shows the positions of the wheels where the maximum strokes occur when the material flow is from left to right. Similarly, FIG. 9 shows a step wise representation 60 of the relative positions of the primary 34 and secondary 40 eccentric counterweights for every 90° clockwise rotation 62 of the secondary eccentric counterweights 40 . The phase illustration 64 to the right of the nine-step series 60 shows the positions of the wheels where the maximum strokes occur when the material flow is from right to left.
From the foregoing, it will be appreciated that a flat stroke bi-directional vibratory conveyor made according to the invention produces a number of advantages over the prior art apparatus. For one, wheel sizes are greatly reduced without loss of stroke force. More particularly, the present invention utilizes a 2:1 frequency ratio and a 1:3 eccentric force ratio that results in the wheel sizes to be [(2×2)×1]:[1×3] or a 4:3 ratio for wheel size. Furthermore, the size of the wheels are even smaller because the present invention's lower frequency stroke is amplified by the sub-resonant tuned frequency of the trough, thereby further reducing the 4:3 ratio to around 1.75:3 ratio. In other words, by adapting the motor to the secondary frequency, motor eccentric counterweight wheels are small, and further, the primary eccentric counterweight wheels are minimized because of the sub-resonant tuning of the conveyor.
By way of example, assume that the conveyor trough natural frequency is set to be around 7% above the primary frequency. So, if the primary frequency is 300 rpm then the trough frequency is set to 320 rpm. The combined result is that the primary running frequency of 300 rpm is amplified as a sub-resonant natural frequency single mass conveyor system. The primary and secondary counterweight wheels have approximately the same brute force stroke. Because the primary natural frequency is close to the primary running speed, the trough stroke amplifies by a factor of about three times the brute force stroke.
It will therefore be appreciated that a flat-stroke bi-directional conveyor made according to the principles of the present invention provides considerable advancements over the aforementioned deficiencies of the prior art.
While a particular embodiment of the invention has been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made therein without departing from the invention in its broader aspects, and, therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true sprit and scope of the invention.
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A flat stroke bi-directional conveyor for conveying object, granular and powder material. The unit utilizes the skewed sine wave trough stroke principle using primary eccentric counterweights wheels driven by a motor running at the secondary speed and equipped with the secondary eccentric counterweight wheels. The forces not in line with the trough stroke are absorbed with an isolation spring mounted between the drive assembly and the base.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Application Ser. No. 61/592,510, filed Jan. 30, 2012, which is hereby incorporated by reference in its entirety.
SUMMARY OF THE INVENTION
[0002] This application provides CaFolate and therapeutics methods based thereon.
[0003] In one embodiment CaFolate is an immune-modulator via MO or TDO (tryptophan 2,3-dioxygenase) pathways. In another embodiment is a method of treating cancer comprising administration of a composition comprising CaFolate. In another embodiment is the method wherein the CaFolate in-vivo transformed to calcium pterin [CaPterin].
[0004] In another embodiment is the method wherein administration of the CaFolate results in decreased IL-6 levels. In another embodiment is the method wherein administration of the CaFolate results in increased IL-10 levels. In another embodiment is the method wherein administration of the CaFolate results in decreased IFN-γ levels. In another embodiment is the method wherein administration of the CaFolate results in increased kynurenine levels. In another embodiment is the method wherein administration of the CaFolate results in increased IL-12 levels. In another embodiment is the method wherein administration of the CaFolate results in decreased IL-6 levels. In another embodiment is the method wherein administration of the CaFolate results in increased IL-4 levels.
[0005] In another embodiment is the method wherein administration of the CaFolate results in inhibition of indoleamine 2,3-dioxygenase.
[0006] In another embodiment is the method wherein administering the CaFolate is through oral, parenteral, intravenous, subcutaneous, intrathecal, intramuscular, buccal, intranasal, epidural, sublingual, pulmonary, local, rectal, or transdermal administration.
[0007] In another embodiment is the method further comprising additional therapies selected from one or more of radiation therapy, chemotherapy, high dose chemotherapy with stem cell transplant, hormone therapy, and monoclonal antibody therapy.
[0008] In another embodiment is the method wherein the cancer is selected from the group consisting of: oral cancer, prostate cancer, rectal cancer, non-small cell lung cancer, lip and oral cavity cancer, liver cancer, lung cancer, anal cancer, kidney cancer, vulvar cancer, breast cancer, oropharyngeal cancer, nasal cavity and paranasal sinus cancer, nasopharyngeal cancer, urethra cancer, small intestine cancer, bile duct cancer, bladder cancer, ovarian cancer, laryngeal cancer, hypopharyngeal cancer, gallbladder cancer, colon cancer, colorectal cancer, head and neck cancer, parathyroid cancer, penile cancer, vaginal cancer, thyroid cancer, pancreatic cancer, esophageal cancer, Hodgkin's lymphoma, leukemia-related disorders, mycosis fungoides, and myelodysplastic syndrome.
[0009] In another embodiment is a method of modulating the immune response comprising administration of a composition comprising CaFolate.
[0010] In another embodiment is a method of treating an inflammatory-based disease or disorder comprising administration of a composition comprising CaFolate. In another embodiment is the method wherein the inflammatory-based disease or disorder is selected from infectious diseases, neurodegenerative disorders, multiple sclerosis, HIV-associate dementia, AIDS dementia, Alzheimer's disease, central nervous system inflammation, obesity, dementia (various forms), coronary heart disease, diabetes (Type 1 and Type 2), atherosclerosis, chronic inflammatory diseases, autism, neonatal onset multisystem inflammatory disease, (also known as NOMID, Chronic Neurologic Cutaneous and Articular Syndrome, or CINCA), Parkinson's Disease, rheumatoid arthritis, osteoarthritis, tendinitis, bursitis, inflammatory lung disease, psoriasis, chronic obstructive pulmonary disease, lupus erythematosus, organ inflammation (e.g. myocarditis, asthma, nepHritis, colitis), inflammatory bowel disease (IBD), autoimmune disease, inflammatory bowel syndrome (IBS), Crohn's Disease, Chronic Ulcerative Colitis, transplant rejection, sepsis, disseminated intravascular coagulation (DIC), septic shock, psoriasis, emphysema and ischemia-reperfusion injury. In another embodiment is the method wherein administering the composition is through oral, parenteral, intravenous, subcutaneous, intrathecal, intramuscular, buccal, intranasal, epidural, sublingual, pulmonary, local, rectal, or transdermal administration.
[0011] In another embodiment is the method wherein the inflammatory-based disease or disorder is hepatitis B virus infection. In another embodiment is the method wherein administering the composition is through oral, parenteral, intravenous, subcutaneous, intrathecal, intramuscular, buccal, intranasal, epidural, sublingual, pulmonary, local, rectal, or transdermal administration. In another embodiment is the method further comprising additional therapies selected from one or more of interferon α, pegylated interferon α-2a, lamivudine, adefovir, tenofovir, telbivudine and entecavir. In another embodiment is the method further comprising additional therapies selected from one or more Amikin, Avelox, Capastat, Cipro, levaquin, kantrex, Myambutol. In another embodiment is the method further comprising additional therapies selected from one or more of ActoPlus Met, Amaryl, Avandia, Byetta, GlucopHage, Glucotrol, Glucovance, Humalog, Janumet, Kombiglyze XR, Lantus, Levemir, Novolog, Onglyza, Prandin, Tradjenta, Victoza, Welchol.
INCORPORATION BY REFERENCE
[0012] All publications, patents, and patent applications mentioned in this specification are herein incorporated by reference to the same extent as if each individual publication, patent, or patent application was specifically and individually indicated to be incorporated by reference.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The novel features of the invention are set forth with particularity in the appended claims. A better understanding of the features and advantages of the present invention will be obtained by reference to the following detailed description that sets forth illustrative embodiments, in which the principles of the invention are utilized, and the accompanying drawings of which:
[0014] FIG. 1 : Structure for CaFolate chelate and CaPterin chelate.
[0015] FIG. 2 : Dipterinyl calcium pentahydrate (DCP) chelate.
[0016] FIG. 3 : activity and neopterin excretion both were suppressed by CaPterin.
DETAILED DESCRIPTION OF THE INVENTION
[0017] CaFolate and Folic acid works with vitamin B12 and vitamin C to help the body break down, use, and make new proteins. The vitamin helps form red blood cells. It also helps produce DNA, the building block of the human body, which carries genetic information. Folate, or folic acid, is a widely recognized vitamin that has been proven to cure a host of human ailments (National Center for Biotechnology Information USNLoM, Folate Deficiency, PubMed Health, 2011). Studies have in nude mice with MDA-MB-231 human breast xenograft tumors with CaFolate have shown anti-tumor activity. The tumor shrank in these mice possessing high levels of endogenous folate and consumed a level of dietary folic acid during the course of treatment. The structure of CaFolate has the same hetro-aromatic ring than CaPterin ( FIG. 1 ). It has been observed that under acidic conditions, UV-irradiation of folic acid (pteroylglutamic acid) causes its successive oxidative cleavage to pterin-6-aldehyde, then to pterin-6-carboxylic acid, and finally to pterin as the end product (Lowry O H, Bessey O A and Crawford E J. PHotolytic and enzymatic transformations of pteroylglutamic acid. J Biol Chem. 1949: 180: 389-98).
[0000]
[0018] FIG. 1 : Structure for Calcium Folate chelate and Calcium Pterin chelate
[0019] Previously it has been reported that Pterin is an immuno-modulator present in the blood and tissues of mammals. It is excreted in the urine of cancer patients in elevated amounts relative to normal persons (Sten B, Halpern R M, Halpern B C and Smith R A, Urinary excretion levels of unconjugated pterins in cancer patients and normal individuals. Clin Can Acta. 1981; 113: 231-42). When combined with calcium, oral Pterin demonstrates anti-tumorgenic (Moheno P, Pfleiderer W, DiPasquale A G, Rheingold A L and Fuchs D. Cytokine and IDO metabolite changes effected by calcium pterin during inhibition of MDA-MB-231 xenograph tumors in nude mice. Int J PHarm. 2008; 355: 238-48; Moheno P, Pfleiderer W and Fuchs D. Plasma cytokine concentration changes induced by the antitumor agents dipterinyl calcium pentahydrate (DCP) and related calcium pterins. Immunobiology. 2009; 214: 135-41; Moheno P B. Calcium pterin as an antitumor agent. Int J PHarm. 2004; 271: 293-300), anti-viral such as hepatitis B (Moheno P, Morrey J and Fuchs D. Effect of dipterinyl calcium pentahydrate on hepatitis B virus replication in transgenic mice. J Transl Med. 2010; 8: 32), anti-diabetic (Nikoulina S E, Fuchs D and Moheno P. Effect of Orally Administered Dipterinyl Calcium Pentahydrate (DCP) on Oral Glucose Tolerance in DIO Mice. ( Diabetes, Metabolic Syndrome and Obesity: Targets and Therapy, 2012; in press) and anti-mycobacterial (BCG) activity in an in vitro model of tuberculosis (Sakala I G, Blazevic A, Moheno P and Hoft D F. Dipterinyl Calcium Pentahydrate inhibits intracellular mycobacterial growth in human monocytes via the C—C chemokine MIP-1beta and Nitric Oxide. Unpublished manuscript. 2011). It has been reported that a promising new cancer therapeutic, dipterinyl calcium pentahydrate (DCP), a dimer of pterin linked together with calcium (DCP) ( FIG. 2 ), shows the same immune-modulatory activities as the monomer CaPterin such as anti-tumor, anti-infective and anti-diabetic activity.
[0000]
[0020] FIG. 2 : X-ray crystallographic structure of dipterinyl calcium pentahydrate (DCP)
[0021] The sensitivity of CaFolate to acidic conditions, suggests that in-vivo, under acidic conditions it is transformed into CaPterin and exhibits the same profile of biological efficacies as CaPterin and DCP.
[0022] Materials and Methods
EXAMPLE 1
[0023] In Vivo Tumor Studies
[0024] A series of in vivo studies provided initial evidence for an immunologically mediated antitumor mechanism for oral 1:4 mol:mol calcium pterin [CaPterin] in suspension (Moheno P B. Calcium pterin as an antitumor agent. Int J PHarm. 2004; 271: 293-300).
[0025] First, six- to eight-month-old C3H/HeN-MTV+ female mice, retired breeders, with a high propensity (˜90%) to develop mammary gland adenocarcinomas within a few weeks after their arrival, were received from the NCI. As each mouse developed a palpable tumor, it was assigned alternately to either Test or Control groups. The mice in the Test group received 3/16 ml of the CaPterin suspension (7 mg/kg/day) by oral gavage for seven days. The ratio of Test tumor volumes to Control tumor volumes (T/C) at Day 7 was 0.1 or 10%.
[0026] Second, athymic nude (nu/nu) female mice, age three to four weeks, were injected subcutaneously with 5×10 6 MDA-MB-231 human breast cancer cells into the right leg. When the tumors reached a mean diameter of 3-5 mm, the mice were divided into two groups, of eight members each. The mice were treated by oral gavage once daily for 14 days with either 3/16 ml of the vehicle control (deionized H 2 O) or with 3/16 ml of the CaPterin suspension (7 mg/kg/day). The mean V/Vo was plotted as a function of time after treatment, giving a T/C=0.41 or 41% after 14 days. No treatment toxicity was found as assessed by reductions in body weight during and after dosing.
[0027] Third, Balb/c female mice, age three to four weeks, were implanted subcutaneously in the right flank with 2×10 7 EMT6 mouse mammary tumor cells. The mice were treated once daily for 15 consecutive days with either an oral injection of vehicle control ( 3/16 ml deionized H2O) or 7 mg/kg/day of 3/16 ml CaPterin suspension. The CaPterin suspension treatment produced no significant effect on tumor growth in the Balb/c mice with EMT6 allograpHs, and no measurable animal toxicity, as determined by decreased body weight.
[0028] Fourth, oral CaPterin suspension was tested in SCID mice bearing the human breast tumor cell line MDA-MB-231. Thirty-two SCID mice were inoculated with scraped MDA-MB-231 human breast cancer cells in matrigel using a subcutaneous flank injection. The mice were randomly assigned, eight mice to each of the following treatment groups: Control (distilled water); 13 mg/kg CaPterin; 20 mg/kg CaPterin; and 26 mg/kg CaPterin. Administration of either CaPterin or the vehicle by oral gavage was from Monday through Friday for 75 days. The CaPterin suspension showed no antitumor efficacy in the SCID mice. The experimental SCID mice demonstrated no measurable toxicity over the 75 days of CaPterin suspension administration.
[0029] Taken together, these results indicate CaPterin's antitumor activity is immunologically mediated, via indoleamine 2,3-dioxygenase (IDO) tumor escape mechanism (Uyttenhove C, Pilotte L, Theate I, et al. Evidence for a tumoral immune resistance mechanism based on tryptophan degradation by indoleamine 2,3-dioxygenase. Nat Med. 2003; 9: 1269-74).
EXAMPLE 2
[0030] In Vitro Studies
[0031] Test for the IDO inhibition (Winkler C, Schroecksnadel K, Moheno P, Meebergen E, Schennach H and Fuchs D. Calcium-pterin suppresses mitogen-induced tryptophan degradation and neopterin production in peripheral blood mononuclear cells. Immunobiology, 2006; 211: 779-84).
[0032] Effect of CaPterin on freshly isolated human peripheral blood mononuclear cells (PBMC) stimulated with the mitogens phytohaemagglutinin and concanavalin A in vitro measure IDO (indoleamine 2,3-dioxygenase) activity, the kynurenine to tryptophan ratio (kyn/trp) was calculated and expressed as umol kynurenine/mmol tryptophan, both determined by High Pressure Liquid ChromatograpHy. Neopterin concentrations were determined by ELISA with a detection limit of 2 nmol/l.
[0033] Results
[0034] Table 1 shows in supernatants of unstimulated PBMC average concentrations of tryptophan and kynurenine were (mean±S.E.M.): 17.7±1.0 and 4.1±0.6 mmol/l, kyn/trp was 251±42.7 nmol/mmol). In the unstimulated PBMC, the addition of the CaPterin did not significantly affect concentrations of tryptophan nor of kynurenine, kyn/trp was lower in cells treated with the highest 200 mg/ml concentration (p<0.05). Concentration of neopterin was 8.1±0.7 nmol/l in unstimulated cells; the addition of the CaPterin did not influence this level.
[0035] Stimulation of cells with PHA decreased tryptophan concentrations to 0.2±0.1 mmol/l, in parallel, kynurenine concentrations increased to 14.4±1.4 mmol/l. Activation of IDO, as quantified by a decrease of tryptophan and a parallel increase of kynurenine concentrations and expressed as kyn/trp, was increased nearly 500-fold in stimulated compared with unstimulated PBMC (p<0.01). Stimulation of cells with Con A decreased tryptophan concentration to 0.4±0.1 mmol/l and increased kynurenine concentration to 14.4±1.6 mmol/l, resulting in significantly higher kyn/trp (p<0.01). The suspension of CaPterin suppressed stimulation-induced tryptophan degradation in a dose-dependent manner: tryptophan levels increased to baseline and kynurenine as well as kyn/trp significantly declined (≦100-fold decrease with PHA stimulation, p<0.001; and ≦500-fold decrease with Con A stimulation, p<0.001).
[0036] Stimulation of PBMC increased neopterin concentrations to 26.6±1.8 nmol/l for PHA and 43.7±7.5 nmol/l for Con A (both p<0.01). Addition of CaPterin to PHA- and Con A-stimulated cells had a significant suppressive effect (≦37% with PHA stimulation, p<0.001; and ≦58% with Con A stimulation, p<0.001).
[0037] At the concentrations tested, no toxicity could be observed by the tryptophan blue exclusion method. FIG. 3 : Table presenting IDO activity and neopterin excretion both were suppressed by CaPterin.
[0000]
Tryptophan
Kynurenine
Kynurenine/Tryptophan
Neopterin
(μM)
(μM)
(μM/mM)
(nM)
Unstimulated
17.7 ± 1.0
4.1 ± 0.6
251 ± 42.7
8.1 ± 0.7
PBMC
Unstimulated
No significant
No significant
Significant decrease
No significant
PBMC + 200
change
change
(p < .05)
change
μg/ml CaPterin
PBMC + PHA
0.2 ± 0.1
14.4 ± 1.4
≦500-fold increase
26.6 ± 1.8
(p < .01)
PBMC + PHA +
17.7 (baseline)
≦100-fold decrease
≦100-fold decrease
≦37% decrease
CaPterin
(p < .001)
(p < .001)
(p < .001)
PBMC + Con
0.4 ± 0.1
14.4 ± 1.6
Significant increase
43.7 ± 7.5
A
(p < .01)
PBMC + Con
17.7 (baseline)
≦100-fold decrease
≦500-fold decrease
≦58% decrease
A + CaPterin
(p < .001)
(p < .001)
(p < .001)
EXAMPLE 3
[0038] In vivo MDA-MB-231 Tumor Studies (Moheno P, Pfleiderer W, DiPasquale A G, Rheingold A L and Fuchs D. Cytokine and IDO metabolite changes effected by calcium pterin during inhibition of MDA-MB-231 xenograph tumors in nude mice. Int J PHarm. 2008; 355: 238-48; Moheno P, Pfleiderer W and Fuchs D. Plasma cytokine concentration changes induced by the antitumor agents dipterinyl calcium pentahydrate (DCP) and related calcium pterins. Immunobiology. 2009; 214: 135-41)
[0039] Studies into the effectiveness of various forms of calcium pterin were next carried out in an experiment with the following aims,
1. To determine a dose response curve for the (1:4 mol/mol) calcium pterin [CaPterin] suspension. 2. To compare the antitumor activity of this suspension to pterin alone (pterin control). 3. To test the effect of CaPterin mega-dosing at 100 mg/(kg day).
[0043] Twenty-three athymic nude (nu/nu) female mice, ages 3-4 weeks, were injected subcutaneously with 5×10 6 MDA-MB-231 cancer cells into the right flank. The four treatment groups were: 1:4 mol/mol) calcium pterin [CaPterin] (7 mg/(kg day)); pterin (21 mg/(kg day)); 1:4, mol/mol) calcium pterin [CaPterin] (21 mg/(kg day)); and sterile water control. CaPterin generated a dose-response relationship reaching a T/C=37% at 21 mg/(kg day) after 60 days of treatment. Pterin at 21 mg/(kg day) was found to have no antitumor activity.
[0044] DCP (dipterinyl calcium pentahydrate) was studied in another experiment with three aims:
1. To test the antitumor effect of the increased [Ca +2 ] in a (1:2 mol/mol) calcium pterin suspension as compared to the (1:4 mol/mol) calcium pterin [CaPterin] suspension; 2. To evaluate the antitumor efficacy of DCP at two concentrations, 23 and 69 mg/(kg day); and 3. To evaluate the antitumor activity of calcium chloride alone (CaCl 2 control).
[0048] In this experiment, 29 athymic nude were each injected subcutaneously with 10×10 6 MDA-MB-231 cancer cells into the right flank. The five treatment groups were: (1:4 mol/mol) calcium pterin [CaPterin] (21 mg/(kg day)); (1:2 mol/mol) calcium pterin (25 mg/(kg day)); DCP (23 mg/(kg day)); DCP (69 mg/(kg day)); and calcium chloride dihydrate (4.2 mg/(kg day)). Blood was collected from all animals via cardiac puncture at termination (after 70-98 days of treatment) and processed to EDTA plasma for analysis. (1:2 mol/mol) calcium pterin (T/C=25%) and DCP at 23 and 69 mg/(kg d) (T/C=25% and T/C=50%; respectively) strongly inhibited MDA-MB-231 xenograph growth in the nude mice. Calcium chloride dihydrate also showed significant efficacy (T/C=25%) attributable to the high levels of endogenous folate-derived pterin in mice and to their dietary folate intake (HED=11 mg/day).
[0049] There was no observed toxicity, as determined by body weight changes, among any of the mice in either of these experiments. Moreover, there was no observed toxicity (appreciable Weight loss≧10%) among any of the mice mega-dosed by oral gavage with 100 mg/(kg day) CaPterin for up to 31 days.
[0050] A stepwise regression analysis of the following plasma measures: IL-1b, IL-2, IL-4, IL-6, IL10, IL-12, IFN-γ, TNF-α, kynurenine, tryptophan, and kyn/trp; yielded a CaPterin regression model significant to p=0.047:
[0000] CaPterin dose [mg/(kg d)]=10.5−0.096 [IL-6 pg/ml]+0.31 [IL-10 pg/ml]−3.16 [IFN-γ pg/ml]+7.89 [kyn μM]
[0051] This regression shows that CaPterin decreases IL-6 and IFN-y, and increases IL-10 and kynurenine. The kynurenine term is confounded by the fact that as tumors shrink, tryptophan plasma levels increase due to decreasing tumor cell growth demands, providing more IDO substrate.
[0052] A similar stepwise regression analysis for plasma IL-1b, IL-2, IL-4, IL-6, IL-10, IL-12, IFN-γ, and TNF-α; yielded a DCP antitumor plasma cytokine pattern (APCP) regression model significant to p=0.003:
[0000] DCP/APCP mg/(kg d))=7.235−0.002 [IL-12 pg/ml]−0.846 [IL-4 pg/ml]+0.051 [IL-6 pg/ml ]
[0053] This regression shows that for the DCP treated mice tumor growth, strongly correlated to DCP/APCP, decreases with IL-12 and IL-4, and increases with IL-6.
EXAMPLE 4
[0054] In Vivo hepatitis B animal model study (Moheno P, Morrey J and Fuchs D. Effect of dipterinyl calcium pentahydrate on hepatitis B virus replication in transgenic mice. J Transl Med. 2010; 8: 32)
[0055] In this study with hepatitis B virus HMO transgenic mice, DCP was administered per os. once daily for 14 days at 23, 7.3, and 2.3 mg/(kg d). DCP caused a significant dose-response reduction of log liver HBV DNA as measured by PCR in the female HBV mice in the 2.3 to 23 mg/(kg d) range. 23 mg/(kg d)) DCP showed an 83% inhibition, comparable to adefovir dipivoxil (ADV) at 10 mg/(kg day). A stepwise regression of serum Tryptophan, Kynurenine, Kyn/Trp; HBV DNA [Southern], HBV DNA [PCR], HBV RNA [PCR], HBe antigen [ELISA]; Average # Liver HBcAg Nuclei per Total, Average # Liver HBcAg Cytoplasms per Total, Average # Liver HBcAg Nuclei per Quarter Field; IL-1a, IL-1b, IL-2, IL-3, IL-4, IL-6, IL-9, IL-10, IL-12, MCP-1, TNF-a, GM-CSF, RANTES, and liver IL-6; log HBV DNA [Southern], log rel. HBV DNA [PCR], log HBV RNA [PCR], and log HBe antigen [ELISA] gave the following DCP measured effects regression (p=0.001):
[0000] DCP dose (mg/(kg/d))=26.309−0.22 [MCP-1 rel. pg/ml]−4.065 [Log rel. HBV DNA (PCR)]−0.560 [kyn/trp uM/mM]+0.070 [GM-CSF rel. pg/ml]
[0056] Results: DCP decreased FIBV DNA as measured by PCR decreased the IDO activity serum kyn/trp. The chemokine MCP-1 was reduced.
[0057] Serum presence of GM-CSF was increased.
EXAMPLE 5
[0058] In vitro study of DCP inhibition on intracellar mycobacterial growth in human monocytes (Sakala I G, Blazevic A, Moheno P and Hoft D F. Dipterinyl Calcium Pentahydrate inhibits intracellular mycobacterial growth in human monocytes via the C—C chemokine MIP-1beta and Nitric Oxide. Unpublished manuscript. 2011)
[0059] Tuberculosis remains one of the top three leading causes of morbidity and mortality.
[0060] Worldwide; complicated by the emergence of drug-resistant Mycobacterium tuberculosis strains and high rates of HIV co-infection. In this study, the ability of DCP to mediate killing of intracellular mycobacteria within human monocytes was tested. DCP treatment of infected monocytes resulted in a significant reduction in viability of intracellular but not extracellular M. bovis BCG. DCP potentiated monocyte antimycobacterial activity by induction of the C—C chemokine MIP-1β, and inducible nitric oxide synthase 2.
Addition of human anti-MIP-1β neutralizing antibody or a specific inhibitor of the L-arginase-nitric oxide pathway (L-NMMA monoacetate), reversed the inhibitory effects of DCP on intracellular mycobacterial growth. Results DCP induced mycobacterial killing via MIP-1β and nitric oxide dependent effects. Hence, DCP acts as an immunoregulatory compound enhancing the anti-mycobacterial activity of human monocytes. IDO gene expression was also suppressed in the infected monocytes by DCP.
EXAMPLE 6
[0064] In Vivo study of orally administered DCP on Oral Glucose Tolerance in DIO Mice ( Diabetes, Metabolic Syndrome and Obesity: Targets and Therapy. 2012; in press)
[0065] DCP as a novel therapeutic for Type 2 diabetes. Female DIO mice, C57BL/6J, fed a high-fat diet were administered DCP orally in 0.4% carboxymethylcellulose for 21 days. Blood glucose was followed during the dosing period, and an oral glucose tolerance test (OGTT) was carried out on day 21 after DCP administration, along with measurements of plasma indoleamine 2,3-dioxygenase (IDO) metabolites (tryptophan and kynurenine), and certain cytokines and chemokines (GM-CSF, IFNγ, IL-1α, IL-1β, IL-4, IL-6, IL-10, IL-12(p40), IL-12(p70), IL-13, MCP-1, RANTES, and TNFα). 7 mg/(kg d) DCP reduced OGTT/AUC (area under OGTT curve) by 50% (p<0.05). A significant multivariate regression p=0.013; R 2 =0.571) of OGTT/AUC was derived from DCP dosage and plasma tryptophan:
[0000] GTT/AUC=0.009 DCP 3 +31.178 DCP 2 −574.513 DCP+29.828 Trp+1935.382
[0066] Elevated plasma tryptophan was found to correlate with higher OGTT/AUC diabetic measures, possibly via inhibition of histamine degradation.
[0067] Conclusion:
[0068] An optimum dose of 7 mg/(kg d) DCP significantly improved the OGTT diabetic state in these female DIO mice.
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Disclosed herein are methods for the treatment of cancer and inflammatory-based diseases and disorders, such as hepatitis B virus infection, tuberculosis and type 2 diabetes based upon the administration of CaFolate. In one embodiment is a method of treating cancer comprising administration of CaFolate. In another embodiment is a method of treatment inflammatory-based disease and disorders comprising administration of CaFolate.
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BACKGROUND OF INVENTION
[0001] The present invention relates to a connector for connecting two or more panels of stone or concrete together.
[0002] The use of slabs of stone in pieces of furniture is well known and in particular slabs of stone are commonly connected together to form a base for a table or to form a desk-top. Currently there are several commonly used systems for connecting stone panels. One such system involves the use of epoxy to join the panel sections. However, in this system, the glued joints must finished by the stone fabricator after the joining has occurred. Further, this type of panel construction takes up a large volume of shipping space and the amount of breakage during shipping is relatively high as the shape of the finished panel is generally quite fragile. The gluing of stone panels together takes a considerable amount of labour time and cannot be subsequently disassembled for moving or storage.
[0003] Another system that is used to join stone panels has been adapted from a system used to connect glass panels. In this system, the edge of the stone is inserted into slot and a set screw is then tightened onto the stone's surface. This system is dependent upon having panels of consistent thickness and often stone panels will not have such uniform widths. In the stone industry variances of 2 millimieters for 2-3 centimeter thick panels are common but variances are often greater. Also, the set screws have a tendency to work loose through time causing the owner to have to have to continually tighten them or risk connection failure.
[0004] Therefore, there is a need in the art for an improved system for connecting stone or concrete panels that overcomes the problems with the current systems as discussed above.
SUMMARY OF INVENTION
[0005] The present invention is directed to an apparatus for attaching panels of stone or concrete to similar panels or to other objects.
[0006] Accordingly, in one aspect of the invention, the invention comprises an apparatus for connecting panels of stone or concrete comprising:
[0007] (a)a connector comprising a body having a central longitudinal axis and at least two faces, wherein each face defines a longitudinal slot, each slot having an open end and an enclosed end, and each slot having a transverse profile comprising a lip;
[0008] (b)at least two bolts, each such bolt having an elongate shaft for attachment into a stone panel and a head comprising a shape matching the transverse profile of the slots, such that the head may be inserted into the open end of a slot, moved longitudinally within the slot and is retained within the slot by the lip.
[0009] In one embodiment, the bolt head and slot “dovetail” together to allow movement along a longitudinal axis of the slot but to prevent movement transverse to the longitudinal axis.
[0010] In another embodiment the apparatus the slot is inclined with the slot being deeper at the enclosed end of the slot than it is at the open end, such that the head of the bolt is drawn towards the center of the connector as it is moved from the open end of the slot to the closed end of the slot.
[0011] In another aspect, the invention comprises a furniture base comprising at least two stone panels connected by means of the apparatus described herein.
[0012] In another aspect, the invention comprises a method of joining two stone panels each having two major surfaces and a joining edge, comprising the steps of:
[0013] (a)attaching at least one bolt into the joining edge of each stone panel, wherein each bolt comprises a head having an enlarged portion;
[0014] (b)connecting the at least one bolt of each stone panel together by means of a connector body having a central longitudinal axis and at least two faces, wherein each face defines a longitudinal slot, each slot having an open end and an enclosed end , and each slot having a transverse profile comprising a lip, wherein the enlarged portion of a bolt head may slide longitudinally within a slot but is retained by the lip.
[0015] In another aspect, the invention comprises an apparatus for joining a stone or concrete piece to another object, comprising:
[0016] (a)a connector comprising a body having a central longitudinal axis and at least one face defining a longitudinal slot having an open end and an enclosed end, and having a transverse profile comprising a lip;
[0017] (b)means for attaching the connector to the object;
[0018] (c)a bolt having an elongate shaft for attachment into a stone panel and a head comprising a shape matching the transverse profile of the slots, such that the head may be inserted into the open end of a slot, moved longitudinally within the slot and is retained within the slot by the lip.
[0019] In one embodiment, the connector body comprises at least two faces and the means for attaching the connector to the object is a clip having a head comprising a shape matching the transverse profile of the slots, such that the head may be inserted into the open end of a slot, moved longitudinally within the slot and is retained within the slot by a lip. The clip further includes arms which position or retain the connector body within the object.
BRIEF DESCRIPTION OF DRAWINGS
[0020] The invention will now be described by way of an exemplary embodiment with reference to the accompanying simplified, diagrammatic, not-to-scale drawings. In the drawings:
[0021] [0021]FIG. 1 is a schematic depiction of one embodiment of a connector. FIG. 1A shows the connector in combination with four panels. FIG. 1B shows an alternative arrangement of four panels.
[0022] [0022]FIG. 2 is a side view in section of one embodiment of a bolt inserted into a stone panel.
[0023] [0023]FIG. 3 is a top view of one embodiment of a bolt.
[0024] [0024]FIG. 4 is a side view in section of one embodiment of a bolt inserted into a stone panel.
[0025] [0025]FIG. 5 is a top view of a cross section of a connector.
[0026] [0026]FIG. 6 is a top view of a cross section of a connector with two bolts inserted into the slots.
[0027] [0027]FIG. 7 is a top view of one embodiment of the invention.
[0028] [0028]FIG. 8 is a top view of one embodiment of a connector and attached stone panels.
[0029] [0029]FIG. 9 is a top view of a side to end attachment configuration.
[0030] [0030]FIG. 10 is a top view of one embodiment of the invention showing the use of a connector and bolt to attach a stone piece to a vertical surface.
[0031] [0031]FIG. 11 is a sectional view of the embodiment of FIG. 10.
[0032] [0032]FIG. 12 is a front view of the embodiment of FIG. 10 showing the clip arms in dotted line.
DETAILED DESCRIPTION
[0033] The apparatus ( 10 ) according to the Figures comprises a connector ( 26 ) and at least two bolts ( 30 ). The connector ( 26 ) has a first ( 12 ) and second end ( 14 ) and at least one slot ( 16 ). The slots ( 16 ) are elongated vertically and have an open end ( 22 ) at the first end of the connector ( 14 ) and an enclosed end ( 24 ) proximate to the second end of the connector ( 12 ). As used herein, the term “vertical” shall mean the direction between the first and second ends of the connector. The term “horizontal” is of course transverse to the vertical direction. In one embodiment the slots ( 16 ) are cavities recessed into the exterior surface of the connector ( 26 ). The inside edge ( 20 A) of the cavity ( 20 ) has a width greater than or equal to the diameter of the head of the bolts ( 34 ). The outside edge ( 20 B) of the cavity ( 18 ) has a width less than the diameter of the head of the bolt ( 34 ). Accordingly the cavity ( 28 ) is wedge shaped in the horizontal plane, as depicted in the end view of one embodiment shown in FIG. 5 with the outer edge of the cavity ( 18 ) forming a lip that retains the bolt ( 30 ) when it is inserted into the slot ( 16 ) as depicted in FIG. 6. In a further embodiment the cavity ( 28 ) may further comprise a rectangular groove ( 40 ) situated inside the inside edge of the cavity ( 20 ) as shown in FIGS. 5 and 6. A wedge shaped cavity may be created such that it matches the shape of the bolt head ( 34 ) as shown in FIG. 6.
[0034] In a further embodiment the slots ( 16 ) are tapered such that the lower edge of the cavity ( 20 ) is deeper at the enclosed end of the slot ( 24 ) and the distance between the lower edge ( 20 ) and the upper edge ( 18 ) is greater at the enclosed end ( 24 ). This creates a thicker lip at the enclosed end ( 24 ). This results in the bolt ( 30 ) being drawn towards the center of the connector ( 26 ) as it moves from the open end ( 22 ) to the closed end ( 24 ). This in turn draws the attached stone panel closer to the connector ( 26 ). Preferably, the dimensions of the connector and the bolt are such that the connector contacts the stone panel when the connector, bolt and stone panel are assembled together. Relatively tight contact between the connector and the stone panel contributes to the stability of the assembly.
[0035] The connectors ( 26 ) may be used to join two or more panels together as depicted in FIGS. 1A, 7, 8 and 9 . The shape of the connector ( 26 ) and the orientation of the slots ( 16 ) can be varied depending on the desired relative position of the stone panels ( 32 ) to each together after they have been connected. If the connector ( 26 ) is square and has four slots ( 16 ) as shown in FIG. 1, then obviously it may be used to connect four stone panels in an “X” pattern as shown in FIG. 1 A. Alternatively, panels may be joined in a square pattern using four connectors as shown in FIG. 1B. The connectors in FIG. 1B obviously require slots on only 2 sides.
[0036] The dimensions or shape, or both, of the connector ( 26 ) may be altered for aesthetic or practical reasons. The connector may have any number of faces and slots, which dictates how many panels the connector may be used in connection with. As shown in FIGS. 5 and 6, the connectors may have two opposing slots, which permits the connector to join panels end to end. As shown in FIG. 8, the connector may have three slots and a triangular shape.
[0037] The connector ( 26 ) may be used to connect the edges of panels as shown in FIGS. 7 and 8, or if thick stone panels are being used, the edge of one panel may be adjoined to the side of another panel a shown in FIG. 9. The shapes of the sides of the connectors ( 26 ) may be varied to ensure that they sit flush to the stone surface that the bolt has been mounted into.
[0038] As depicted in FIGS. 2, 3 and 4 the bolts have shaft ( 36 ) and a head ( 34 ). The bolt ( 30 ) is inserted into the stone panel by drilling a hole corresponding to the size of the shaft ( 36 ) and by then inserting the shaft ( 36 ) into the hole along with appropriate epoxy. The shaft ( 36 ) may be any number of shapes depending on the size and nature of the stone panels being connected. In one embodiment the shaft ( 36 ) is substantially cylindrical as shown in FIGS. 2 and 3 and is threaded to facilitate better adhesion to the epoxy. For a cylindrical shaft a typical stone drill bit can make the plughole for the shaft to be set into. In another embodiment as shown in FIG. 4, the shaft ( 36 ) is flat with a rectangular cross-section, suitable for narrow stone panels. For such a flat shaft, a typical stone-cutters blade may be used to make the slot in the panel for the shaft ( 36 ) to be set into.
[0039] As depicted in FIGS. 2 and 4, in one embodiment, the bolt head ( 34 ) comprises a cylindrical portion ( 34 A) and a wedge portion ( 34 B). The cylindrical portion is cylindrical in shape immediately adjacent to the attachment point to the shaft ( 36 ) and accordingly has a shoulder which rests against the stone upon installation. The length of this cylindrical portion may be varied to match the depth of the slots in the connector. The wedge portion has an increasing diameter which fits within and is retained by the slots described above. If the bolt head ( 34 ) is circular when view head-on, which is not necessarily the case, the wedge portion will of course be conical. If the bolt head is square when viewed head-on, the wedge portion will be pyramidal. This shape of the bolt head may be varied to any shape that matches the corresponding slot in the connector.
[0040] The use of such inserted bolts ( 30 ) to attach to the connector ( 26 ) means that the system is not vulnerable to failure if the thickness of the panels to be connected vary. Further, the bolts can be installed on site and do require finishing by a stone fabricator. This also means that the stone panels do not have to be shipped connected together reducing both cargo space and the incidence of breakage during shipping.
[0041] The connectors ( 26 ) and bolts ( 30 ) may be constructed from woods, plastics and metals or such other materials as are suitable and as would be selected by one skilled in the art.
[0042] As shown in FIG. 7, connectors ( 26 ) may be linked by rods or bars ( 40 ) to cover open space spans between the panels. If such rods or bars ( 40 ) are used it may be preferable that a restraining clip or pin should be mounted on the bottom of the connector ( 26 ) to prevent someone's foot or leg from striking the bar or rod ( 40 ) and knocking the connectors ( 26 ) off the panels.
[0043] The use and operation of the apparatus ( 10 ) will now be described with reference to the Figures. Holes are drilled into the edges of the stone panels ( 32 ) at identical heights. The bolt shafts ( 36 ) are inserted and fixed with an adhesive such as an epoxy. The bolt head ( 34 ) shoulder is set against the surface of the stone. One of the panels ( 32 ) is held a vertical position and the open end ( 22 ) of a slot ( 16 ) on the connector ( 26 ) is aligned with the top of the bolt head ( 34 ) such that the slot ( 16 ) is parallel to the surface that the bolt ( 30 ) has been inserted into. The connector ( 26 ) is then pushed downwards causing the bolt head ( 34 ) to move up the slot ( 16 ). Because the slot is tapered inward toward the central axis of the connector, the stone panel and connector are drawn together until they contact or until the bolt head reaches the enclosed end of the slot ( 16 ). The enclosed end of the slot ( 24 ) prevents the connector ( 26 ) from sliding off the bolt head ( 34 ) and gravity prevents the connector ( 26 ) from working itself loose. The process is then repeated for the second panel to be attached to the connector ( 26 ). When joining two vertical panels it is preferred that a minimum of two connectors ( 26 ) and 4 bolts ( 30 ) be used to promote stability and to prevent undue stress on the connectors. The connector ( 26 ) may be removed from the bolts ( 30 ) by striking it on its lower or first end ( 14 ) causing the connector ( 26 ) to move up and off the bolts. In a preferred embodiment the top of the connector ( 26 ) may have a threaded hole ( 13 ) to facilitate its removal with a threaded rod (not shown).
[0044] In another embodiment, the connector of the present invention may be used to attach stone or concrete panels to an object with a vertical surface. In one example, as illustrated in FIGS. 10 and 11, a stone mantle support bracket ( 50 ) may be attached to a stone lintel ( 52 ). A connector ( 26 ) as described above may be inserted into a groove cut into the top of the lintel ( 52 ). Preferably the connector closely fits the dimensions of the groove and is the same width. In this embodiment, the connector slot openings are oriented upwards, to receive the bolt head of a bolt ( 30 ) which has been inserted into the bracket ( 50 ). The bolt ( 30 ) will then be supported vertically and retained horizontally within the connector ( 26 ) to attach the bracket ( 50 ) to the lintel ( 52 ).
[0045] On the reverse side of the connector and lintel, a retaining clip ( 54 ) has a head ( 56 ) which is configured identically to the bolt head, so as to engage the connector slot in the same manner. As seen in FIGS. 10 and 12, the laterally extending arms ( 58 ) of the clip prevent the connector from sliding out in a forward direction. If the connector is narrower or wider than the thickness of the lintel, the arms ( 58 ) of the clip may be bent backwards or forwards to retain the connector substantially flush with the front surface of the lintel.
[0046] As will be apparent to those skilled in the art, various modifications, adaptations and variations of the foregoing specific disclosure can be made without departing from the scope of the invention claimed herein.
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The present invention relates to a connector for connecting two or more panels of stone together. In one embodiment of the invention, the invention comprises a connector having a body with a first and a second end and at least two symmetrically orientated slots, each slot having an open end and an enclosed end. The invention is further comprised of at least two bolts, each such bolt having a shaft for attachment into a stone panel and a head protruding from the surface of the stone panel, the outer edge of the head having a consistent diameter suitable for insertion into the open end of a slot on the connector wherein bolt head is inserted into the open end of the slot and moved through the slot to a secure position proximate to the enclosed end.
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CROSS REFERENCE TO RELATED APPLICATIONS
The present application claims priority benefit from U.S. provisional patent applications 61/511,583 filed 26 Jul. 2011 and 61/523,360 filed 14 Aug. 2011.
FIELD
The present disclosure relates to shape of the combustion chamber and injector orientation in internal combustion engines.
BACKGROUND
Thermal efficiency and engine-out emissions from an internal combustion engine are determined by many factors including the combustion chamber shape, the fuel injection nozzle, fuel injection pressure, to name a few. Much is known and much has been studied in typical diesel engine combustion chambers. However, in unconventional engines, less is known about what combustion chamber shape and fuel injection characteristics can provide the desired performance.
Such an unconventional engine, an opposed-piston, opposed-cylinder (OPOC) engine 10 , is shown isometrically in FIG. 1 . An intake piston 12 and an exhaust piston 14 reciprocate within each of first and second cylinders (cylinders not shown to facilitate viewing pistons). An intake piston 12 ′ and an exhaust piston 14 couple to a journal (not visible) of crankshaft 20 via pushrods 16 . An intake piston 12 and exhaust piston 14 ′ couple to two journals (not visible) of crankshaft 20 via pullrods 18 . The engine in FIG. 1 has two combustion chambers formed between a piston top 22 of intake piston 12 (or 12 ′) and a piston top 24 of exhaust piston 14 (or 14 ′) and the cylinder wall (not shown). The pistons in both cylinders are shown at an intermediate position in FIG. 1 . Combustion is initiated when the pistons are proximate each other. The piston tops 22 and 24 in FIG. 1 may not be optimized to provide the desired performance. The piston top 24 has a raised region at the periphery and a flat bowl in the middle of the chamber. To achieve a desired compression ratio, the volume contained in the piston bowls is prescribed. Piston top 24 has a raised region, known by one skilled in the art as squish. The projected area of the squish region is a small portion of the projected area of piston top 24 , whereas the bowl is the greater portion of the projected area. Because of the large area taken up by the bowl, the depth of the bowl is limited. Such a shallow bowl allows little space to accommodate fuel jets from an injector to enter the combustion chamber without significantly impinging on piston top surfaces.
SUMMARY
A combustion chamber that induces tumble flow is disclosed. The combustion chamber includes a cylinder wall; an intake piston disposed within the cylinder wall; an exhaust piston disposed within the cylinder wall; and a first fuel injector disposed in an opening that pierces the cylinder wall. The pistons are adapted to reciprocate within the cylinder walls. When tops of the pistons are at their closest approach, the combustion chamber located between the tops of the piston forms first and second regions: the first region being substantially a cone proximate the injector with a tip of the cone closer to the first injector and a base of the cone away from the first injector and the second region being substantially a hemisphere with a flat surface of the hemisphere substantially coincident with a base of the cone. The pistons are configured to reciprocate between an upper and a lower position and the cone provides a line-of-sight opening between a tip of the first injector and the hemisphere. A cross section of the pistons taken through a central axis of the cylinder which is 90 degrees rotated from intersecting the injector toward the hemisphere of the combustion chamber shows the tops of the two pistons on each side of the hemispherical region of the combustion chamber sloped so that a thin ribbon that exists between the two piston tops when the pistons are at their closest approach is substantially tangent to a periphery of the hemisphere. When the pistons approach each other, gases between the two pistons are squeezed into the conical and hemispherical region inducing a vortex. The vortex is a tumble flow with an axis of rotation of tumble flow is substantially perpendicular to a central axis of the cylinder wall. A cross section of the pistons coincident with the base of the cone shows the tops of the two pistons on each side of the hemisphere is sloped so that thin ribbons that exist between the two piston tops when the pistons are at their closest approach are substantially tangent to a periphery of the hemisphere.
Some embodiments include a second fuel injector disposed in a second opening that pierces the cylinder wall. The second fuel injector is in an opposed arrangement with respect to the first injector. When tops of the pistons are at their closest approach, the combustion chamber located between the tops of the piston also forms third and fourth regions: the third region being substantially a cone proximate the second injector with a tip of the cone closer to the second injector and a base of the cone away from the second injector and the fourth region being substantially a hemisphere with a flat surface of the hemisphere of the fourth region coincident with a base of the cone of the third region. The hemisphere of the fourth region and the hemisphere of the second region do not overlap. A cross section of the pistons coincident with the base of the cone of the first region shows the tops of the two pistons on each side of the hemisphere of the second region sloped so that thin ribbons that exist between the two piston tops when the pistons are at their closest approach are substantially tangent to a periphery of the hemisphere of the second region and a cross section of the pistons coincident with the base of the cone of the third region shows the tops of the two pistons on each side of the hemisphere of the fourth region sloped so that thin ribbons that exist between the two piston tops when the pistons are at their closest approach are substantially tangent to a periphery of the hemisphere of the fourth region. When the pistons approach each other, gases between the two pistons that are squeezed out into the hemispherical region of the second region generate a tumble flow in a first direction. When the pistons approach each other, gases between the two pistons that are squeezed out into the hemispherical region of the fourth region also generate a tumble flow substantially in the first direction. In an alternative embodiment, when the pistons approach each other, gases between the two pistons that are squeezed out into the hemispherical region of the fourth region generate a tumble flow in a direction having an opposite sense as the first direction.
A combustion chamber is disclosed having a cylinder wall; an intake piston disposed within the cylinder wall; an exhaust piston disposed within the cylinder wall; and first and second fuel injectors disposed in first and second openings that pierce the cylinder wall with the first and second injectors substantially opposed to each other. The pistons are adapted to reciprocate within the cylinder walls. When tops of the pistons are at their closest approach, the combustion chamber located between the tops of the piston defines a first cone with a tip of the cone substantially coincident with a tip of the first injector and a base of the cone located away from the first injector; a second cone with a tip of the second cone coincident with a tip of the second injector and a base of the cone located away from the second injector; a first hemisphere with a base of the first hemisphere coincident with a base of the first cone; and a second hemisphere with a base of the second hemisphere coincident with a base of the second cone. When tops of the pistons are at their closest approach, the first and second cones and the first and second hemispheres are arranged substantially along a diameter defined by tips of the first and second injectors and the first and second hemispheres do not intersect. When the pistons approach each other, gases between the tops of the pistons other than between the first and second cones and the first and second hemispheres are squeezed into the first and second cones and the first and second hemispheres; and the piston tops are arranged so that the gases squeezed into the first and second hemispheres generates tumble flows. The intake piston has a raised portion on one side of the a plane intersecting tips of the first and second injectors and parallel to a central axis of the cylinder; the exhaust piston has a corresponding recessed portion on one side of the plane; the intake piston has a recessed portion on the other side of the plane; and the exhaust piston has a corresponding raised portion on the other side of the plane. The tumble flow in the first hemisphere rotates in substantially the same direction as the tumble flow in the second hemisphere. Considering first, second, third, and fourth quadrants of the piston tops, the intake piston has raised portions in the first and third quadrants, the intake piston has recessed portions in the second and fourth quadrants, the exhaust piston has recessed portions in the first and third quadrants, and the exhaust piston has raised portions in the second and fourth quadrants. The raised and recessed portions are exclusive of the cones and hemispheres defined in the piston tops. The second quadrant is located between the first and third quadrants. The raised portions of the piston tops index with the recessed portions of the piston tops to develop a tumble flow in the first hemisphere in a first direction and a tumble flow in the second hemisphere in a second direction with the second direction in an opposite sense with respect to the first direction.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric drawing of an OPOC engine;
FIGS. 2-4 are cross-sectional views of a single-injector, tumble-inducing combustion chamber according to an embodiment of the present disclosure;
FIGS. 5 and 6 are cross-sectional views of a dual-injector, tumble-inducing combustion chamber according to an embodiment of the present disclosure in which two tumble flows rotating in substantially the same direction are induced;
FIG. 7 is an isometric view of the top of the intake piston of FIGS. 5-6 ;
FIGS. 8 and 9 are cross-sectional views of a dual-injector, tumble-inducing combustion chamber according to an embodiment of the present disclosure with the tumble flows in the hemispherical counter rotating, i.e., in opposite directions;
FIG. 10 is an isometric views of the top of the intake piston;
FIG. 11 is an isometric view of the top of the exhaust piston, respectively, of FIG. 10 with counter-rotating tumble flows;
FIG. 12 is an illustration of fuel spray and combustion from a single fuel jet.
FIGS. 13 and 14 shown an alternative embodiment in which a single combustion bowl is offset from the center;
FIGS. 15-18 are illustrations to describe how to form piston tops according to an embodiment of the disclosure;
FIGS. 19-21 and 23 are isometric drawings of pistons according to several embodiments of the disclosure;
FIG. 22 is a cross-sectional view of the embodiment of FIG. 21 ; and
FIG. 24 is a method to make a piston according to an embodiment of the disclosure.
DETAILED DESCRIPTION
As those of ordinary skill in the art will understand, various features of the embodiments illustrated and described with reference to any one of the Figures may be combined with features illustrated in one or more other Figures to produce alternative embodiments that are not explicitly illustrated or described. The combinations of features illustrated provide representative embodiments for typical applications. However, various combinations and modifications of the features consistent with the teachings of the present disclosure may be desired for particular applications or implementations. Those of ordinary skill in the art may recognize similar applications or implementations whether or not explicitly described or illustrated.
A cross section of a portion on an OPOC engine illustrating a combustion chamber according to an embodiment of the disclosure is shown in FIG. 2 . A portion of intake piston 40 and a portion of exhaust piston 42 are shown at their closest position. Piston 40 has grooves 44 and 45 and piston 42 has grooves 46 and 47 to accommodate piston rings. For convenience in illustration, piston rings are not shown in the grooves in FIG. 2 nor in following figures illustrating pistons. Pistons 40 and 42 reciprocate within cylinder wall 50 . The combustion chamber is the volume enclosed between the tops of pistons 40 and 42 and the cylinder wall 50 . The tops of the pistons in their closest position are separated by at least 0.5 mm. Those skilled in the art appreciate that the minimum distance of separation varies depending on the particulars of the engine including size, tolerances, etc. Such range is provided as an example and not intended to be limiting.
In FIG. 2 , a single-injector embodiment with an injector 60 is shown. The opening between pistons 40 and 42 in region 52 is substantially conical with a tip of the cone located proximate injector 60 . The cross section of the opening increases to accommodate expanding fuel jets emanating from injector 60 . Distal from injector 60 the opening between pistons 40 and 42 , in region 54 , is substantially a hemisphere. Fuel from injector 60 has momentum to travel through region 52 and potentially into region 54 . However, much of the fuel has vaporized and the momentum of the liquid drops is reduced by shear with the compressed gases in the combustion chamber. Thus, if the injector hole size and fuel injection pressure characteristics are chosen carefully, few droplets impact the far wall of the combustion chamber from injector 60 .
An alternative cross section, which is rotated 90 degrees from FIG. 2 is shown in FIG. 3 , a view from the injector tip. The hemispherical shape of region 54 of FIG. 2 is more easily viewed in FIG. 3 . The shape of the tops of pistons 40 and 42 promote tumble flow, i.e., a vortex with an axis of rotation substantially perpendicular with respect to the central axis of the central axis 66 of cylinder walls 50 . A portion 64 of the top of piston 42 angles upward toward axis 66 and a portion 62 of piston 40 angles downward toward axis 66 . As pistons 40 and 42 move toward each other, they force the gases between them to exit tangentially as illustrated by arrow 70 . Similarly, portion 56 of the top of piston 40 and portion 58 of the top of piston 42 , during a compression stroke, cause gases to exit tangentially as illustrated by arrow 72 . The flows shown by arrows 70 and 72 interacting with the hemispherical region of the combustion chamber generate a tumble flow, as illustrated by arrow 74 . Such tumble flow aids in mixing the fuel with the air to improve the combustion efficiency and reduce generation of diesel particulates.
The combustion chamber, per the view in FIG. 3 , shows that the piston tops have an upward slope, as considered from left to right to facilitate generating tumble flow in the combustion chamber.
In FIG. 4 , jets 68 exit from injector 60 into the combustion chamber. Tips of jets 68 have not reached region 54 at the time illustrated in FIG. 4 . In FIG. 4 , three jets are visible with additional jets possibly being occluded by the visible jets. However, any number of jets may exit injector 60 .
It is desirable to have one injector supply fuel to the combustion chamber. However, if jets 68 from the one injector are unable to access the air in the cylinder to effectively utilize inducted air, a second injector may be provided in the cylinder. Such an embodiment with two injectors 160 in cylinder 150 is shown in FIG. 5 . Two combustion chamber portions that are smaller versions of the combustion chamber of FIGS. 2 and 3 are provided in FIG. 5 . Regions 152 of the combustion chamber that are proximate injectors 160 are substantially conical; regions 154 of the combustion chamber that are distal from injector 160 substantially form a hemisphere.
An alternative view of the pistons in FIG. 5 is shown in FIG. 6 . The alternative view is rotated 90 degrees with respect to FIG. 5 , i.e., a view as seen by a tip of one of injectors 160 . A portion 162 of the surface of piston 142 and a portion 164 of piston 140 are angled upward to the right so that during a compression stroke, gases between portions 162 and 164 are squeezed as shown by arrow 170 . Analogously, a portion 158 of piston 142 and a portion 156 of piston 140 slope upwards as taken from left to right so that gases between portions 156 and 158 are directed as shown by arrow 172 . These flows, as illustrated by arrows 170 and 172 , form a tumble flow as illustrated by circular arrow 174 .
The top of piston 140 is shown isometrically in FIG. 7 illustrating portions 158 and 164 in which the tumble in the two bowls rotates in the same general direction.
An alternative with counter-rotating tumble flows is shown in FIG. 8 . Two injectors 260 are disposed in cylinder 250 and the volume between pistons 240 and 242 form two combustion chambers. Regions 252 of the combustion chamber that are proximate injectors 260 are substantially conical; regions 254 of the combustion chamber that are distal from injector 260 substantially form a hemisphere. Referring back to the embodiment in FIG. 5 , the view of the combustion chamber shows that the primary portions of the combustion chamber surface is formed in intake piston 140 . FIGS. 5-7 are different views of the same embodiment in which the tumble flows rotate in substantially the same direction. FIGS. 8-11 are views of an embodiment in which the tumble flows substantially counter-rotate. In the view of the combustion chamber illustrated in FIG. 8 , in which the tumbles are counter rotating. The portion of the combustion chamber visible in FIG. 9 causes a tumble flow 274 from the jets of gases 270 and 272 that are squeezed out when pistons 240 and 242 move toward each other during a compression stroke.
An isometric view of the top of piston 240 is shown in FIG. 10 . Rather than the raised portion of the piston being on one side of the piston, as is the case in FIG. 7 , raised portions 280 of piston 240 are opposite each other (across from each other with respect to axis 266 ), i.e., in quadrants across from each other with respect to central axis 266 . Recessed portions 282 of the top of piston 240 are also arranged opposite each other. In FIG. 11 , an isometric view of exhaust piston 242 is show with jets 268 spraying into the combustion chamber portions. Three jets 268 from each injector 260 are visible in FIG. 11 . Additional jets may exit injector 260 , but are not visible in FIG. 11 . Alternatively, an injector with fewer or more jets may be used. Exhaust piston 242 has raised portions 290 diametrically opposed to each other and depressed portions 292 diametrically opposed to each other. Depressed portions 290 of exhaust piston 242 move toward raised portions 280 of intake piston 240 during reciprocation during operation. Depressed portions 282 of intake piston 240 move toward raised portions 292 of exhaust piston 242 . Due to the depressed portions of each piston being adjacent a recessed portion, the direction of the tumble flow in the two combustion chamber portions are of opposite sense or counter-rotating.
In FIG. 12 , a representation of combustion of a diesel jet is shown. The fuel emanates from an orifice 300 of a fuel injector (not shown). The liquid drops travel through a region 302 with vaporization occurring. The fuel jets spreads in region 304 and due to vaporization of the fuel, a fuel rich zone develops in region 304 . The jet continues forward and autoignition of premixed fuel and air ensues when fuel and air in a combustible mixture reach a temperature for a sufficient duration to autoignite. After the premixed fuel burns, a diffusion flame forms on the periphery of the jet in region 306 . Soot forms within region 308 , much of which is burned when the soot mixes with air. The fuel from the jet is contained substantially within a conical region 320 connected with a hemispherical region 322 . The combustion chambers described herein are substantially conical with a hemisphere at the end, i.e., similar to the envelope which contains the fuel jet shown in FIG. 12 .
An embodiment in which the combustion chamber is defined preferentially in a piston 350 in FIGS. 13 and 14 . In FIG. 13 , it can be seen that piston 350 has a deep bowl while piston 352 has a shallower bowl. Also shown in FIG. 13 is an end view of fuel jets 354 from an injector (not shown). The example in FIG. 13 is a four jet injector at a location in which the jets have overlapped. FIG. 14 is a cross section taken at 90 degrees rotated from FIG. 13 in which the cross section is taken through injector 356 .
To aid in the description of the combustion chamber, a series of piston shapes leading up to the embodiment in FIGS. 13 and 14 are used. The intake and exhaust pistons, other than in the area of the combustion chamber, are substantially conical. Blanks of the pistons are shown in cross section in FIG. 15 : piston 370 is conical (in a positive fashion) and piston 372 is negatively conical.
If the combustion chamber were to be taken out of the center from the exhaust piston as illustrated in FIG. 16 , a tumble flow would not be generated. The squish flow on both sides is directed upwards as illustrated by the arrows. By displacing the combustion chamber toward one side, a feature can be added to cause the flow to tumble.
In the cross section shown in FIG. 17 , the combustion bowl 360 is offset to the left of central axis 358 toward the left. On the left hand side of combustion bowl 360 , the piston tops of both pistons slope upwards to the right. On the right hand side of combustion chamber, the interface between the two pistons also slope upwards to the right. However, this deviates from the purely conical shape, which is indicated by dashed line 361 . A portion of the cone that would be in exhaust piston 350 is removed, i.e., the portion indicated by region 362 . Region 362 is part of intake piston 352 (but would be part of exhaust piston if the conical shapes of FIG. 15 had remained). The benefit of this feature shown by region 362 is illustrated in FIG. 18 . The squish flow generated from the interface between intake piston 352 and exhaust piston 350 when they approach each other on the left hand side of combustion bowl 360 causes an upward flow, similar to that shown in FIG. 16 . An arrow is illustrating this upward flow in FIG. 18 . On the right hand side of combustion bowl 360 , a downward flow is generated when the pistons approach each other thereby causing a tumble flow in combustion bowl 17 , as illustrated by the circular arrow.
In FIG. 19 , an isometric view of piston 350 is shown. As discussed above in regards to the cross-sectional view of piston 350 in FIG. 17 , the shape of the piston on one side of combustion bowl 360 is different than on the other side. A transition region 364 is provided across from injector 356 . In such a location, the transition region has little impact generating tumble flow as the desired geometry is provided along the majority of the fuel jet trajectory.
Piston 352 is shown isometrically in FIG. 20 and shows the offset nature of the combustion chamber and separately shows the combustion chamber. It is difficult to discern that piston 352 is concave from the two-dimensional drawing in FIG. 20 . Nevertheless, as piston 352 is concave, it is known to one skilled in the art, that combustion bowl 356 is less deep than in embodiments in FIGS. 2-11 . This may present an advantage in scavenging the combustion bowl region. However, the embodiments in FIGS. 2-11 are lighter and have fewer regions at which hot spots could form and thus may have some other advantages. The selection of the combustion chamber shape may depend on the ultimate application.
As discussed above, the 352 can be consider as starting out as a cone defined in the piston top, i.e, a negative cone. However, due to the desire to promote tumble flow, the region 361 , as shown in FIG. 17 , is built up. Thus, in some embodiments, the piston blank for piston 352 is not a negative cone, but has additional material formed in region 361 . Region 361 has a fairly pointed tip extending downwardly toward exhaust piston 350 . This forms a ridge in piston 352 . It is advantageous that combustion bowl 360 is offset so that the ridge in region 361 is more nearly centrally located than it would be if combustion bowl 360 were centrally located. Thus, interference of the intake flow by the ridge of region 361 is minimized.
In the above discussion, an injector with one or more orifices is discussed and shown in various figures. Alternatively, an injector with an outwardly opening pintle can be used. Such an injector provides a spray which is a hollow cone. The angle of the cone can be varied by varying the geometry of the injector tip. In FIG. 21 , an isometric view of exhaust piston 350 is shown with a conical spray 382 is directed into combustion bowl 362 . A cross section of the pistons and the conical spray is also illustrated in FIG. 22 . Such a spray may benefit vaporization by allowing air to access the inner and outer surfaces of the conical spray. A pintle-type injector can be used in place of the multi-hole injector in any of the embodiments.
FIGS. 2-4 show a single-injector embodiment while FIGS. 5-7 show a dual-injector embodiment that is analogous to the embodiment of FIGS. 2-4 . That is, the combustion bowls in FIGS. 5-7 are scaled down proportionally to accommodate two of the bowls shown in FIGS. 2-4 . The embodiment of the single-injector embodiment shown in FIGS. 13-14 can be similarly extended to a dual-injector embodiment.
In FIG. 23 piston 350 is shown in an isometric view. The combustion bowl is comprised of a reentrant portion of a sphere 380 and a conical region 382 that provides a passage from an injector tip region 390 (injector not shown) to the portion of sphere 380 . Material is removed from the blank piston in the region of 361 . Referring back to FIG. 18 , this provides the ability, in cooperation with piston 352 , to direct the gases downward into combustion bowl 360 .
One method of making a piston is shown in FIG. 24 . A piston is formed that has a top that is convexly conical 400 . This is referred to a vertical cone for the purposes of discussion when viewing the piston with its central axis oriented vertically. The piston may be a unitary piston or be made of a plurality of elements. The portion including the piston top includes the cone. A spherical combustion bowl is formed in the cone and is offset from a central location 402 . The portion of the combustion bowl formed in the exhaust piston is reentrant in the embodiment shown in FIG. 23 . The sphere that is defined in the exhaust piston is a truncated sphere as a portion of the combustion bowl is also formed in the intake piston (not shown). A horizontally-arranged conical passage is defined in the piston top 404 . The tip of the cone is arranged near the tip of the injector with the base of the cone coinciding with the sphere. The cone opens up to the combustion bowl to allow fuel jets, which are expanding after exiting the injector, to access the combustion bowl. A portion of the remaining cone is removed on one side of the combustion bowl to provide a recess. The recess in the exhaust piston with the corresponding built up area on the intake piston (as shown in FIG. 23 ) direct flow downwardly into the combustion bowl to promote tumble flow. Processes 402 - 204 in FIG. 24 can be performed in any order.
While the best mode has been described in detail with respect to particular embodiments, those familiar with the art will recognize various alternative designs and embodiments within the scope of the following claims. While various embodiments may have been described as providing advantages or being preferred over other embodiments with respect to one or more desired characteristics, as one skilled in the art is aware, one or more characteristics may be compromised to achieve desired system attributes, which depend on the specific application and implementation. These attributes include, but are not limited to: cost, strength, durability, life cycle cost, marketability, appearance, packaging, size, serviceability, weight, manufacturability, ease of assembly, etc. The embodiments described herein that are characterized as less desirable than other embodiments or prior art implementations with respect to one or more characteristics are not outside the scope of the disclosure and may be desirable for particular applications.
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A combustion chamber in an opposed-piston, internal-combustion engine is disclosed in which the pistons tops are designed so that when they approach each other, they induce a tumble flow in one or two hemispherical spaces defined in the piston tops. The combustion chamber further includes injectors side mounted in the cylinder wall. In one embodiment, the tumble flows in the two hemispheres are in the same direction and in another embodiment, in opposite directions. In yet another embodiment, there is only one injector and one hemisphere in which a tumble flow is induced.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 12/988,165, filed Oct. 15, 2010, now U.S. Pat. No. 9,241,763, which application is the national stage of International Application No. PCT/US2009/002403, filed Apr. 17, 2009.
[0002] Said International Application No. PCT/US2009/002403 claims the benefit of U.S. Provisional Application No. 61/208,315, filed Feb. 23, 2009, and also claims the benefit of PCT Application No. PCT/US2008/013650, filed Dec. 12, 2008. Further, said International Application No. PCT/US2009/002403, also claims the benefit of U.S. Provisional Patent Application No. 61/196,948, filed Oct. 22, 2008.
[0003] Said International Application No. PCT/US2009/002403 also is a continuation-in-part of co-pending U.S. application Ser. No. 12/107,025, filed Apr. 21, 2008, which claims the benefit of each of U.S. Provisional Application No. 60/912,899, filed Apr. 19, 2007, and U.S. Provisional Application No. 61/013,274, filed Dec. 12, 2007, and U.S. Provisional Application No. 61/045,937, filed Apr. 17, 2008. All of the above priority applications are expressly incorporated by reference in their entirety.
[0004] Co-pending U.S. application Ser. No. 12/107,025 also claims priority to each of PCT Application No. PCT/US2008/060935, filed Apr. 18, 2008, and PCT Application No. PCT/US2008/060929, filed Apr. 18, 2008, and PCT Application No. PCT/US2008/060940, filed Apr.18, 2008, and PCT Application No. PCT/US2008/060922, filed Apr. 18, 2008. All of the above priority applications are expressly incorporated by reference in their entirety.
FIELD OF THE INVENTION
[0005] The present application relates to methods, apparatuses and systems for non-invasive delivery of energy, including microwave therapy. In particular, the present application relates to methods, apparatuses and systems for non-invasively delivering energy, such as, for example, microwave energy, to the epidermal, dermal and sub-dermal tissue of a patient to achieve various therapeutic and/or aesthetic results.
DESCRIPTION OF THE RELATED ART
[0006] It is known that energy-based therapies can be applied to tissue throughout the body to achieve numerous therapeutic and/or aesthetic results. There remains a continual need to improve on the effectiveness of these energy-based therapies and provide enhanced therapeutic results with minimal adverse side effects or discomfort.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The invention will be understood from the following detailed description of preferred embodiments, taken in conjunction with the accompanying drawings, wherein:
[0008] FIG. 1 is an illustration of a system including a generator, applicator and disposable according to an embodiment of the invention.
[0009] FIG. 2 is a perspective view of a medical treatment device, including an applicator and disposable, according to an embodiment of the invention.
[0010] FIG. 3 is an end on view of the distal end of a medical treatment device, including an applicator and the disposable according to an embodiment of the invention.
[0011] FIG. 4 is an exploded perspective view of a medical treatment device according to an embodiment of the invention.
[0012] FIG. 5 is a view of a medical treatment device according to an embodiment of the invention including a cutaway view of applicator according to an embodiment of the invention.
[0013] FIG. 6 is a perspective view of a disposable according to an embodiment of the invention.
[0014] FIG. 7 is a view of a proximal side of a disposable according to an embodiment of the invention.
[0015] FIG. 8 is a side view of one end of a disposable according to an embodiment of the invention.
[0016] FIG. 9 is a side view of one end of a disposable according to an embodiment of the invention.
[0017] FIG. 10 is a view of a distal side of a disposable according to an embodiment of the invention.
[0018] FIG. 11 is a side view of a disposable according to an embodiment of the invention.
[0019] FIG. 12 is a cutaway side view of a disposable according to an embodiment of the invention.
[0020] FIG. 13 is a cutaway side view of a disposable according to an embodiment of the invention.
[0021] FIG. 14 is a cutaway perspective view of a disposable according to an embodiment of the invention.
[0022] FIG. 15 is a top perspective view of a proximal end of a disposable according to an embodiment of the invention.
[0023] FIG. 16 is a perspective view of an antenna array according to an embodiment of the invention.
[0024] FIG. 17 is an end view of a portion of an antenna array according to an embodiment of the invention.
[0025] FIG. 18 is a cutaway side view of a portion antenna array according to an embodiment of the invention.
[0026] FIG. 19 is a cutaway side view of a portion antenna array according to an embodiment of the invention.
[0027] FIG. 20 is a simplified cutaway view of a medical treatment device with tissue engaged according to an embodiment of the invention.
[0028] FIG. 21 is a simplified cutaway view of a medical treatment device with tissue engaged according to an embodiment of the invention.
[0029] FIG. 22 is a simplified cutaway view of a medical treatment device with tissue engaged according to an embodiment of the invention.
[0030] FIG. 23 is a graphical illustration of a pattern of lesions in tissue according to an embodiment of the invention.
[0031] FIG. 24 illustrates a treatment template according to an embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0032] Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structures. While the preferred embodiment has been described, the details may be changed without departing from the invention which is defined by the claims.
[0033] FIG. 1 is an illustration of a system 2309 including a generator 2301 , applicator 2320 (which may also be referred to as re-usable) and disposable 2363 according to an embodiment of the invention. According to an embodiment of the invention applicator 2320 and disposable 2363 may comprise a medical treatment device 2300 . According to an embodiment of the invention generator 2301 may operate in the ISM band of 5.775 to 5.825 GHz. According to an embodiment of the invention generator 2301 may have a Frequency centered at approximately 5.8 GHz. According to an embodiment of the invention generator 2301 includes circuitry for setting and controlling output power; measuring forward and reverse power and setting alarms. According to an embodiment of the invention generator 2301 may have a power output of between approximately 40 Watts and approximately 100 Watts. According to an embodiment of the invention generator 2301 may have a power output of between approximately 40 Watts and approximately 100 Watts where said output is measured into a 50 ohm load. According to an embodiment of the invention generator 2301 may have a power output of approximately 55 Watts measured into a 50 ohm load. According to an embodiment of the invention disposable 2363 and applicator 2320 may be formed into two separable units. According to an embodiment of the invention disposable 2363 and applicator 2320 may be formed into a single unit. According to an embodiment of the invention when combined disposable 2363 and applicator 2320 may form a medical treatment device 2300 . According to an embodiment of the invention generator 2301 may be a microwave generator. According to an embodiment of the invention in system 2309 applicator 2320 may be connected to generator 2301 by applicator cable 2334 . According to an embodiment of the invention in system 2309 applicator cable 2334 may include coolant conduit 2324 , energy cable 2322 , coolant thermocouple wires 2331 , cooling plate thermocouple wires 2330 and antenna switch signal 2481 . According to an embodiment of the invention in system 2309 coolant conduit 2324 may be connected to a coolant source 2310 (which may be, for example, a Nanotherm industrial recirculation chiller with 8 pounds per square inch pump output pressure available from ThermoTek, Inc.). According to an embodiment of the invention in system 2309 energy cable 2322 may be connected to generator 2301 by microwave output connector 2443 . According to an embodiment of the invention in system 2309 antenna switch signal 2481 may be connected to generator 2301 by antenna switch connector 2480 . According to an embodiment of the invention in system 2309 disposable 2363 may be connected to generator 2301 by vacuum tubing 2319 which may include generator bio-barrier 2317 , which may be, for example, a hydrophobic filter. According to an embodiment of the invention in system 2309 vacuum tubing 2319 may be connected to generator 2301 by vacuum port connector 2484 . According to an embodiment of the invention in system 2309 front panel 2305 of generator 2301 may include power control knob 2454 , vacuum control knob 2456 , antenna select switch 2462 (which may include both display elements and selection switches), vacuum meter 2486 , antenna temperature display 2458 , coolant temperature display 2460 , pre-cool timer 2468 (which may include both display elements and time set elements), energy timer 2470 (which may include both display elements and time set elements), post-cool timer 2472 (which may include both display elements and time set elements), start button 2464 , stop button 2466 , ready indicator 2476 and fault indicator 2474 . According to an embodiment of the invention an error signal is sent to generator 2301 if a measured signal is outside of the specification for the requested power set by the power control knob 2454 on front panel 2305 . According to an embodiment of the invention vacuum tube 2319 may include a flexible vacuum hose 2329 and a generator bio-barrier 2317 . According to an embodiment of the invention flexible vacuum hose 2329 is adapted to collect fluids, such as, for example sweat or blood, which may escape disposable 2363 so that such fluids do not reach generator 2301 . According to an embodiment of the invention generator bio-barrier 2317 may include a hydrophobic filter to keep fluids out of vacuum port connector 2484 of generator 2301 . According to an embodiment of the invention generator bio-barrier 2317 may include a hydrophobic filter, such as, for example, a Millex FH Filter made of 0.45 micrometer hydrophobic PTFE which is available from Milipore. According to an embodiment of the invention generator bio-barrier 2317 may be positioned in vacuum tube 2319 between flexible vacuum hose 2329 and vacuum port connector 2484 . According to an embodiment of the invention applicator cable 2334 may connect generator 2301 to applicator 2320 . According to an embodiment of the invention cooling plate thermocouple wires 2330 and coolant thermocouple wires 2331 may be connected to generator 2301 by temperature connector 2482 . According to an embodiment of the invention coolant conduit 2324 may convey cooling fluid from a coolant source 2310 to applicator 2320 . According to an embodiment of the invention applicator cable 2334 may convey microwave switch selection data to applicator 2320 and temperature data from thermocouples in applicator 2320 to generator 2301 . According to an embodiment of the invention applicator cable 2334 may comprise one or more separate cables and connectors. According to an embodiment of the invention a generator connector may be designed and adapted to connect applicator cable 2334 to generator 2301 , including connections for cooling conduit 2324 , antenna switch signal 2481 , energy cable 2322 , cooling plate thermocouple wires 2330 and coolant thermocouple wires 2331 .
[0034] FIG. 2 is a perspective view of a medical treatment device 2300 including an applicator 2320 and disposable 2363 according to an embodiment of the invention. According to an embodiment of the invention applicator 2320 may be attached to disposable 2363 by latching mechanism 2365 . According to an embodiment of the invention applicator 2320 may include applicator cable 2334 . According to an embodiment of the invention disposable 2363 may include vacuum tubing 2319 , tissue chamber 2338 and tissue interface surface 2336 .
[0035] FIG. 3 is an end on view of a distal end of a medical treatment device 2300 including an applicator 2320 and disposable 2363 according to an embodiment of the invention. According to an embodiment of the invention disposable 2363 may include tissue bio-barrier 2337 . According to an embodiment of the invention applicator 2320 may include cooling plate 2340 , which may be, for example, positioned behind tissue bio-barrier 2337 . According to an embodiment of the invention tissue bio-barrier 2337 may form a portion of tissue interface surface 2336 . According to an embodiment of the invention latching mechanism 2365 may be used to facilitate the connection of disposable 2363 to applicator 2320 .
[0036] FIG. 4 is a perspective view of a medical treatment device 2300 including an exploded perspective view of an applicator 2320 and a view of disposable 2363 according to the present invention. According to an embodiment of the invention applicator 2320 may include a cooling plate 2340 , separation ribs 2393 , intermediate scattering elements 3393 , antenna cradle 2374 , waveguide assembly 2358 and antenna switch 2357 . According to an embodiment of the invention waveguide assembly 2358 may include antennas 2364 ( a - d ). According to an embodiment of the invention disposable 2363 may include vacuum tubing 2319 , latching elements 2359 and vacuum seal 2348 .
[0037] FIG. 5 is a view of a medical treatment device 2300 according to an embodiment of the present invention including a cutaway view of applicator 2320 and disposable 2363 . According to an embodiment of the invention applicator 2320 may include antenna array 2355 , antenna switch 2357 and applicator cable 2334 . According to an embodiment of the invention applicator cable 2334 may include cooling plate thermocouple wires 2330 , coolant thermocouple wires 2331 , coolant supply tubing 2312 , coolant return tubing 2313 , antenna switch signal 2481 , energy cable 2322 . According to an embodiment of the invention cooling plate thermocouple wires 2330 may include one or more thermocouple wires which may be attached to an or more thermocouples positioned opposite an output of antenna array 2355 . According to an embodiment of the invention coolant thermocouple wires 2331 may include one or more thermocouple wires attached to an or more cooling path thermocouples 2326 which may be positioned to measure coolant fluid, such as, for example, in coolant return tubing 2313 . According to an embodiment of the invention one or more cooling path thermocouples 2326 may be positioned to measure the temperature of cooling fluid 2361 after it passes through coolant chamber 2360 . According to an embodiment of the invention one or more cooling path thermocouples 2326 may be located in coolant return tubing 2313 . According to an embodiment of the invention cooling path thermocouples 2326 may function to provide feedback to generator 2301 indicative of the temperature of cooling fluid 2361 after cooling fluid 2361 passes through coolant chamber 2360 . According to an embodiment of the invention disposable 2363 may include latching element 2359 . According to an embodiment of the invention applicator cable 2334 may include interconnect cables 2372 to transmit signals to antenna array 2355 . According to an embodiment of the invention antenna array 2355 may include antenna cradle 2374 .
[0038] FIG. 6 is a perspective view of disposable 2363 according to an embodiment of the invention. FIG. 7 is a view of the proximal side of disposable 2363 according to an embodiment of the invention. FIG. 8 is a side view of one end of disposable 2363 according to an embodiment of the invention. FIG. 9 is a side view of one end of disposable 2363 according to an embodiment of the invention. FIG. 10 is a view of the distal side of disposable 2363 according to an embodiment of the invention. FIG. 11 is a side view of disposable 2363 according to an embodiment of the invention. FIG. 12 is a cutaway side view of disposable 2363 according to an embodiment of the invention. FIG. 13 is a cutaway side view of disposable 2363 according to an embodiment of the invention. FIG. 14 is a cutaway perspective view of disposable 2363 according to an embodiment of the invention. FIG. 15 is a top perspective view of a proximal end of disposable 2363 according to an embodiment of the invention.
[0039] According to an embodiment of the invention disposable 2363 may include tissue interface surface 2336 , tissue chamber 2338 and alignment features 3352 . According to an embodiment of the invention tissue interface surface 2336 may form a back wall of tissue chamber 2338 . According to an embodiment of the invention tissue interface surface 2336 may include tissue bio-barrier 2337 and vacuum passage 3333 . According to an embodiment of the invention vacuum passage 3333 may also be referred to as a lip or rim. According to an embodiment of the invention disposable 2363 may include alignment features 3352 and vacuum tubing 2319 . According to an embodiment of the invention disposable 2363 may include compliant member 2375 . According to an embodiment of the invention chamber walls 2354 may include a compliant member 2375 . According to an embodiment of the invention compliant member 2375 may be formed from a compliant material, such as, for example, rubber, coated urethane foam (with a compliant plastic or rubber seal coating), silicone, polyurethane or heat sealed open cell foam. According to an embodiment of the invention compliant member 2375 may be positioned around the outer edge of tissue chamber 2338 to facilitate the acquisition of tissue. According to an embodiment of the invention compliant member 2375 may be positioned around the outer edge of chamber opening 2339 to facilitate the acquisition of tissue. According to an embodiment of the invention compliant member 2375 may facilitate the engagement of tissue which is not flat, such as, for example tissue in the axilla. According to an embodiment of the invention compliant member 2375 may facilitate the engagement of tissue which is not flat, such as, for example tissue in the outer regions of the axilla. According to an embodiment of the invention compliant member 2375 may provide improved sealing characteristics between the skin and tissue chamber 2338 , particularly where the skin is not flat. According to an embodiment of the invention compliant member 2375 may speed the acquisition of tissue in tissue chamber 2338 , particularly where the skin is not flat. According to an embodiment of the invention compliant member 2375 may have a height of between approximately 0.15 inches and approximately 0.40 inches above chamber opening 2339 when compliant member 2375 is not compressed. According to an embodiment of the invention compliant member 2375 may have a height of approximately 0.25 inches above chamber opening 2339 when compliant member 2375 is not compressed. According to an embodiment of the invention alignment features 3352 may be positioned at a distance which facilitate appropriate placement of applicator 2320 during treatment. According to an embodiment of the invention alignment features 3352 may be positioned approximately 30.7 millimeters apart. According to an embodiment of the invention alignment features 3352 may be further positioned and may be designed to assist a physician in positioning applicator 2320 prior to the application of energy. According to an embodiment of the invention alignment features 3352 on disposable 2363 assist the user in properly positioning the applicator prior to treatment and in moving the applicator to the next treatment region during a procedure. According to an embodiment of the invention alignment features 3352 on disposable 2363 , when used with marks or landmarks in a treatment region facilitate the creation of a continuous lesion. According to an embodiment of the invention alignment features 3352 may be used to align medical treatment device 2300 before suction is applied. According to an embodiment of the invention an outer edge of compliant member 2375 may assist a user in aligning medical treatment device 2300 .
[0040] According to an embodiment of the invention compliant member 2375 , which may also be referred to as a skirt or flexible skirt, may be manufactured from silicone. According to an embodiment of the invention compliant member 2375 may extend approximately 0.25″ from rigid surface 3500 . According to an embodiment of the invention a counter sink or dovetail notch 2356 may be positioned in rigid disposable surface 3500 around the outer edge of chamber opening 2339 to assist in alignment of compliant member 2375 . According to an embodiment of the invention the compliant member 2375 may have a durometer density rating (softness) of approximately A60 which may help compliant member 2375 to maintain its shape better while being easier to mold. According to an embodiment of the invention colorant may be used in compliant member 2375 to contrast with skin viewed through compliant member 2375 , making it easier for user, such as a physician to distinguish between skin and a distal surface of compliant member 2375 . According to an embodiment of the invention colorant may be used in compliant member 2375 to make it easier for user, such as a physician to distinguish between skin and an outer edge of compliant member 2375 . According to an embodiment of the invention colorant may be used in compliant member 2375 to help a user distinguish an edge of compliant member 2375 from surrounding skin and assist in aligning of medical treatment device 2300 . According to an embodiment of the invention the angle of compliant member 2375 relative to rigid surface 3500 may be approximately 53 degrees when compliant member 2375 is not compressed.
[0041] According to an embodiment of the invention disposable 2363 includes applicator chamber 2346 . According to an embodiment of the invention disposable 2363 may include an applicator chamber 2346 which may be formed, at least in part, by tissue bio-barrier 2337 . According to an embodiment of the invention disposable 2363 may include applicator bio-barrier 2332 (which may be, for example, a polyethylene film, available from Fisher Scientific), and vacuum passage 3333 . According to an embodiment of the invention a counter bore may positioned between applicator bio-barrier 2332 and applicator chamber 2346 .
[0042] According to an embodiment of the invention vacuum passage 3333 connects vacuum channel 3350 to tissue chamber 2338 . According to an embodiment of the invention vacuum channel 3350 may also be referred to as a reservoir or vacuum reservoir. According to an embodiment of the invention vacuum connector 2328 is connected to vacuum passage 3333 through vacuum channel 3350 . According to an embodiment of the invention vacuum channel 3350 may connect vacuum passages 3333 connect vacuum connector 2328 in tissue chamber 2338 . According to an embodiment of the invention vacuum passages 3333 form a direct path to tissue interface surface 2336 . According to an embodiment of the invention vacuum passages 3333 and vacuum channel 3350 may be adapted to restrict the movement of fluids from tissue chamber 2338 to applicator bio-barrier 2332 . According to an embodiment of the invention vacuum connector 2328 may be positioned on the same side of disposable 2363 as applicator bio-barrier 2332 . According to an embodiment of the invention applicator bio-barrier 2332 may be designed to prevent fluids from tissue chamber 2338 from reaching applicator chamber 2346 , particularly when there is back pressure caused by, for example, a vacuum created in tissue chamber 2338 as tissue is pulled away from tissue interface surface 2336 . According to an embodiment of the invention vacuum pressure may be used to support tissue acquisition in tissue chamber 2338 . According to an embodiment of the invention vacuum pressure may be used to pull tissue into tissue chamber 2338 . According to an embodiment of the invention vacuum pressure may be used to maintain tissue in tissue chamber 2338 . According to an embodiment of the invention vacuum channel 2350 may surround tissue interface surface 2336 . According to an embodiment of the invention applicator bio-barrier 2332 may be positioned between vacuum passages 3333 and applicator chamber 2346 . According to an embodiment of the invention applicator bio-barrier 2332 may be a membrane which may be adapted to be permeable to air but substantially impermeable to biological fluids such as, for example, blood and sweat. According to an embodiment of the invention applicator bio-barrier 2332 may be a hydrophobic membrane filter. According to an embodiment of the invention applicator bio-barrier 2332 may be made of polyethylene film, nylon or other suitable materials. According to an embodiment of the invention applicator bio-barrier 2332 may include pores having sizes sufficient to pass enough air to substantially equalize the vacuum pressure in applicator chamber 2346 and in tissue chamber 2338 without passing biological fluids from tissue chamber 2338 to applicator chamber 2346 . According to an embodiment of the invention applicator bio-barrier 2332 may include pores having sizes of approximately 0.45 micrometers. According to an embodiment of the invention when the vacuum is turned on, and before pressure is equalized, applicator bio-barrier 2332 may induce a minimal pressure drop between vacuum passages 3333 and the applicator chamber 2346 . According to an embodiment of the invention applicator chamber 2346 and tissue chamber 2338 may be separated, at least in part, by tissue bio-barrier 2337 . According to an embodiment of the invention tissue chamber 2338 may include tissue interface surface 2336 and chamber wall 2354 .
[0043] According to an embodiment of the invention tissue chamber opening 2339 has dimensions which facilitate the acquisition of tissue. According to an embodiment of the invention tissue chamber 2339 may be sized to facilitate tissue acquisition while being large enough to prevent interference with energy radiated from waveguide antennas 2364 in antenna array 2355 when applicator 2320 is attached to disposable 2363 . According to an embodiment of the invention a vacuum circuit 3341 may include vacuum passages 3333 , vacuum channel 3350 and may encircle tissue chamber 3338 . According to an embodiment of the invention vacuum channel 3350 may be positioned around tissue chamber 2338 . According to an embodiment of the invention vacuum passage 3333 may be positioned around a proximal end of tissue chamber 2338 . According to an embodiment of the invention vacuum passage 3333 may be positioned around a proximal end of tissue chamber 2338 between tissue bio-barrier 2337 and a proximal end of chamber wall 2354 . According to an embodiment of the invention an opening to vacuum passage 3333 may be approximately 0.020 inches in height. According to an embodiment of the invention an opening to vacuum passage 3333 may be approximately 0.010 inches in height when disposable 2363 is attached to applicator 2320 and tissue bio-barrier 2337 is stretched into tissue chamber 2338 by a distal end of applicator 2320 . According to an embodiment of the invention vacuum passage 3333 may have an opening height which is too small for tissue to invade when a vacuum is applied.
[0044] According to an embodiment of the invention disposable 2363 may be manufactured from a clear or substantially clear material to assist a user, such as a physician in viewing tissue engagement. According to an embodiment of the invention the disposable 2363 may have an outer angle to allow a user to see alignment features 3352 on compliant member 2375 to assist a user in aligning medical treatment device 2300 . According to an embodiment of the invention an angle around the outside of disposable 2363 provides a user with a direct view of alignment features 3352 . According to an embodiment of the invention tissue chamber 2338 may have dimensions of approximately 1.54 inches by approximately 0.7 inches. According to an embodiment of the invention the 4 corners of tissue chamber 2338 may have a radius of 0.1875 inches. According to an embodiment of the invention antenna array 2335 may include four antennas and may have dimensions of approximately 1.34 inches by approximately 0.628 inches. According to an embodiment of the invention the dimensions of the waveguide array 2335 and tissue chamber 2338 may be optimized to minimizing stray fields forming at the edges of waveguide array 2335 as well as optimizing the effective cooling area of tissue interface surface 2336 . According to an embodiment of the invention tissue chamber 2338 may be optimized to facilitate tissue acquisition without adversely impacting cooling or energy transmission.
[0045] FIG. 16 is a perspective view of antenna array 2355 according to an embodiment of the invention. According to an embodiment of the invention antenna array 2355 may include antenna cradle 2374 . According to an embodiment of the invention antenna cradle 2374 may include reservoir inlet 2384 and antenna chamber 2377 . According to an embodiment of the invention waveguide assembly 2358 may include one or more spacer 3391 (which may be, for example, copper shims) positioned between waveguide antennas 2364 . According to an embodiment of the invention spacer 3391 may be positioned between waveguide antenna 2364 a and waveguide antenna 2364 b. According to an embodiment of the invention spacer 3391 may be positioned between waveguide antenna 2364 b and waveguide antenna 2364 c. According to an embodiment of the invention spacer 3391 may be positioned between waveguide antenna 2364 c and waveguide antenna 2364 d. According to an embodiment of the invention microwave energy may be supplied to each waveguide antenna through feed connectors 2388 . According to an embodiment of the invention waveguide assembly 2358 may be held together by a waveguide assembly frame 2353 . According to an embodiment of the invention waveguide assembly frame 2353 may include feed brackets 2351 and assembly bolts 2349 . According to an embodiment of the invention antenna array 2355 may include antenna cradle 2374 and least one waveguide antenna 2364 . According to an embodiment of the invention antenna array 2355 may include one or more spacer 3391 . According to an embodiment of the invention antenna array 2355 may include four waveguide antennas 2364 a, 2364 b, 2364 c and 2364 d. According to an embodiment of the invention the heights of waveguide antennas 2364 in antenna array 2355 may be staggered to facilitate access to feed connectors 2388 . According to an embodiment of the invention one or more waveguide antenna 2364 in antenna array 2355 may include tuning element 2390 .
[0046] FIG. 17 is an end view of a portion of antenna array 2355 according to an embodiment of the invention. FIG. 18 is a cutaway side view of a portion antenna array 2355 according to an embodiment of the invention. FIG. 19 is a cutaway side view of a portion antenna array 2355 according to an embodiment of the invention. According to an embodiment of the invention antenna array 2355 includes coolant chambers 2360 (for example coolant chambers 2360 a, 2360 b, 2360 c and 2360 d ), intermediate scattering elements 3393 , separation ribs 2393 and scattering elements 2378 (for example scattering elements 2378 a, 2378 b, 2378 c and 2378 d ). According to an embodiment of the invention scattering elements 2378 may also be referred to as central scattering elements. According to an embodiment of the invention coolant chambers 2360 a - 2360 d may be located beneath waveguide antenna 2364 a - 2364 d. According to an embodiment of the invention coolant chambers 2360 may include separation ribs 2393 on either side of antenna array 2355 and intermediate scattering elements 3393 between antennas 2364 . According to an embodiment of the invention an intermediate scattering element 3393 may be positioned between waveguide antenna 2364 a and waveguide antenna 2364 b. According to an embodiment of the invention an intermediate scattering element 3393 may be positioned between waveguide antenna 2364 b and waveguide antenna 2364 c. According to an embodiment of the invention an intermediate scattering element 3393 may be positioned between waveguide antenna 2364 c and waveguide antenna 2364 d. According to an embodiment of the invention cooling fluid flowing through coolant chambers 2360 may have a flow rate of between approximately 200 milliliters per minute and approximately 450 milliliters per minute and preferably approximately 430 milliliters per minute. According to an embodiment of the invention coolant chambers 2360 may be designed to ensure that the flow rate through each coolant chamber 2360 is substantially the same. According to an embodiment of the invention coolant the flow rate of cooling fluid through coolant chamber 2360 a is the same as the flow rate of cooling fluid through coolant chamber 2360 b. According to an embodiment of the invention coolant the flow rate of cooling fluid through coolant chamber 2360 a is the same as the flow rate of cooling fluid through coolant chambers 2360 b, 2360 c and 2360 d. According to an embodiment of the invention cooling fluid flowing through coolant chamber 2360 may have a temperature of between approximately 8 degrees centigrade and approximately 22 degrees centigrade and preferably approximately 15 degrees centigrade. According to an embodiment of the invention coolant chambers 2360 may be positioned between an aperture of waveguide antenna 2364 cooling plate 2340 . According to an embodiment of the invention scattering elements 2378 may extend into at least a portion of coolant chambers 2360 . According to an embodiment of the invention scattering elements 2378 may extend through coolant chambers 2360 . According to an embodiment of the invention scattering elements 2378 and intermediate scattering elements 3393 may extend through coolant chambers 2360 to contact a proximal surface of cooling plate 2340 . According to an embodiment of the invention elements of coolant chamber 2360 may be smoothed or rounded to promote laminar fluid flow through coolant chambers 2360 . According to an embodiment of the invention elements of coolant chambers 2360 may be smoothed to reduce the generation of air bubbles in coolant chamber 2360 . According to an embodiment of the invention scattering elements 2378 which extend into coolant chambers 2360 may be rounded to promote laminar flow and prevent the buildup of bubbles in coolant chamber 2360 . According to an embodiment of the invention scattering elements 2378 may be formed in the shape of ovals or racetracks. According to an embodiment of the invention square edges or sharp corners in coolant chamber 2360 may result in undesirable flow characteristics, including the generation of air bubbles, as cooling fluid moves through coolant chamber 2360 . According to an embodiment of the invention intermediate scattering elements 3393 may be positioned between separate individual coolant chambers 2360 . According to an embodiment of the invention intermediate scattering elements 3393 may be positioned such that they facilitate equalized cooling across cooling plate 2340 . According to an embodiment of the invention intermediate scattering elements 3393 may be sized such that they have a width which is equal to or less than the separation distance between apertures of waveguide antennas 2364 . According to an embodiment of the invention intermediate scattering elements 3393 may be sized and positioned such that they are not positioned an aperture of waveguide antenna 2364 . According to an embodiment of the invention intermediate scattering elements 3393 may be sized and positioned such that they modify a microwave field as it travels through coolant chamber 2360 . According to an embodiment of the invention intermediate scattering elements 3393 may be sized and positioned such that they modify a microwave field radiated from waveguide antenna 2364 . According to an embodiment of the invention intermediate scattering elements 3393 may be sized and positioned such that they spread out a microwave field as it travels through coolant chamber 2360 . According to an embodiment of the invention intermediate scattering elements 3393 may cause disruption or perturbation of microwave energy radiated from waveguide antenna 2364 . According to an embodiment of the invention intermediate scattering elements 3393 may be made of materials which will not rust or degrade in cooling fluid. According to an embodiment of the invention intermediate scattering elements 3393 may be made of materials which improve the SAR pattern in tissue. According to an embodiment of the invention intermediate scattering elements 3393 may be made of materials, such as dielectric materials, which are used to form scattering elements 2378 . According to an embodiment of the invention FIGS. 17 through 19 may also include waveguide assembly 2358 , feed connectors 2388 , antenna chamber 2377 , spacers 3391 , cradle channels 2389 and antenna cradle 2374 .
[0047] According to an embodiment of the invention intermediate scattering elements 3393 may be positioned between waveguide antennas 2364 . According to an embodiment of the invention the size and shape of the intermediate scattering elements 3393 may be designed to optimize the size and shape of lesions developed in the skin between waveguide antennas 2364 . According to an embodiment of the invention intermediate scattering elements 3393 may make lesions created in tissue between waveguide antennas 2364 larger and more spread out. According to an embodiment of the invention intermediate scattering elements 3393 may make lesions created in tissue between waveguide antennas 2364 narrower. According to an embodiment of the invention intermediate scattering elements 3393 may have an optimal length which is shorter than the length of scattering elements 2378 . According to an embodiment of the invention scattering elements 2378 may be approximately 7 millimeters in length. According to an embodiment of the invention intermediate scattering elements 3393 may have an optimal length which is approximately 6.8 millimeters. According to an embodiment of the invention intermediate scattering elements 3393 may be manufactured from, for example, alumina. According to an embodiment of the invention intermediate scattering elements 3393 may be manufactured from, for example, a material which is approximately 96% alumina. According to an embodiment of the invention intermediate scattering elements 3393 may be manufactured from, for example, silicone. According to an embodiment of the invention the intermediate scattering elements 3393 may be manufactured from a material having the same dielectric constant as scattering elements 2378 . According to an embodiment of the invention the intermediate scattering elements 3393 may be manufactured from a material having approximately the same dielectric constant as scattering elements 2378 . According to an embodiment of the invention intermediate scattering elements 3393 may be manufactured from a material having a dielectric constant of approximately 10. According to an embodiment of the invention intermediate scattering elements 3393 may be manufactured from a material having a dielectric constant of approximately 3. According to an embodiment of the invention increasing the dielectric constant of intermediate scattering element 3393 may reduce the size of a lesion created in skin between waveguide antennas 2364 . According to an embodiment of the invention intermediate scattering elements 3393 may be inserted into tongue and groove slots between wave antennas 2364 . According to an embodiment of the invention thermocouples may be positioned beneath one or more of intermediate scattering elements 3393 . According to an embodiment of the invention thermocouples may be positioned each of intermediate scattering elements 3393 .
[0048] FIGS. 20, 21 and 22 are simplified cutaway views of a medical treatment device 2300 with tissue engaged according to an embodiment of the invention. According to an embodiment of the invention skin 1307 is engaged in treatment device 2300 . According to an embodiment of the invention dermis 1305 and hypodermis 1303 are engaged in medical treatment device 2300 . According to an embodiment of the invention skin surface 1306 is engaged in medical treatment device 2300 such that skin surface 1306 is in thermal contact with at least a portion of cooling plate 2340 . According to an embodiment of the invention skin surface 1306 is engaged in medical treatment device 2300 such that skin surface 1306 is in contact with at least a portion of tissue interface 2336 . According to an embodiment of the invention a vacuum pressure may be used to elevate dermis 1305 and hypodermis 1303 , separating dermis 1305 and hypodermis 1303 from muscle 1301 . According to an embodiment of the invention vacuum pressure may be used to elevate dermis 1305 and hypodermis 1303 , separating dermis 1305 and hypodermis 1303 from muscle 1301 to, for example, protect muscle 1301 by limiting or eliminating the electromagnetic energy which reaches muscle 1301 . According to an embodiment of the invention waveguide assembly 2358 may include one or more waveguide antennas 2364 . According to an embodiment of the invention electromagnetic energy, such as, for example, microwave energy may be radiated into dermis 1305 by medical treatment device 2300 . According to an embodiment of the invention medical treatment device 2300 may include coolant chamber 2360 and cooling plate 2340 . According to an embodiment of the invention a peak which may be, for example, a peak SAR, peak power loss density or peak temperature, is generated in first tissue region 1309 . According to an embodiment of the invention first tissue region 1309 may represent a lesion created by energy, such as, for example, microwave energy radiated from medical treatment device 2300 . According to an embodiment of the invention first tissue region 1309 may represent a lesion created by microwave energy radiated from one or more of waveguide antennas 2364 . According to an embodiment of the invention first tissue region 1309 may be initiated in skin 1307 between first waveguide antenna 2364 and a second waveguide antenna 2364 . According to an embodiment of the invention first tissue region 1309 may be initiated in skin 1307 between first waveguide antenna 2364 a and a second waveguide antenna 2364 b. According to an embodiment of the invention first tissue region 1309 may be initiated in skin 1307 underlying intermediate scattering element 3393 . According to an embodiment of the invention a reduced magnitude which may be, for example, a reduced SAR, reduced power loss density or reduced temperature, is generated in second tissue region 1311 with further reduced magnitudes in third tissue region 1313 and fourth tissue region 1315 . As illustrated in FIGS. 20 through 22 , dermis 1305 is separated from hypodermis 1303 by interface 1308 . As illustrated in FIGS. 20 through 22 interface 1308 may be idealized as a substantially straight line for the purposes of simplified illustration however in actual tissue, interface 1308 may be a non-linear, non-continuous, rough interface which may also include many tissue structures and groups of tissue structures which cross and interrupt tissue interface 1308 . According to an embodiment of the invention electromagnetic radiation may be radiated at a frequency of, for example, between 5 and 6.5 GHz. According to an embodiment of the invention electromagnetic radiation may be radiated at a frequency of, for example, approximately 5.8 GHz. According to an embodiment of the invention scattering element 2378 may be located in coolant chamber 2360 and intermediate scattering elements 3393 may be located between coolant chambers 2360 . According to an embodiment of the invention scattering element 2378 and intermediate scattering elements 3393 may be used to, for example, spread and flatten first tissue region 1309 . According to an embodiment of the invention scattering element 2378 and intermediate scattering elements 3393 may be used to, for example, spread and flatten a region, such as first tissue region 1309 , of peak SAR in tissue. According to an embodiment of the invention scattering element 2378 and intermediate scattering elements 3393 may be used to, for example, spread and flatten a region, such as first tissue region 1309 , of peak power loss density in tissue. According to an embodiment of the invention scattering element 2378 and intermediate scattering elements 3393 may be used to, for example, spread and flatten a region, such as first tissue region 1309 , of peak temperature in tissue. According to an embodiment of the invention scattering element 2378 and scattering elements 3393 may be used to, for example, spread and flatten lesions formed in first tissue region 1309 . According to an embodiment of the invention the creation of lesions, such as for example, a lesion in tissue region 1309 may be used to treat the skin of patients. According to an embodiment of the invention the creation of lesions, such as for example, a lesion in tissue region 1309 may be used to damage or destroy structures, such as, for example, sweat glands in the skin of a patient.
[0049] FIG. 23 is a graphical illustration of a pattern of lesions in tissue according to an embodiment of the invention. According to an embodiment of the invention lesions may be created in a predetermined order, such as, for example A-B-C-D where: A represents a lesion initiated directly under waveguide antenna 2364 a; B represents a lesion initiated directly under waveguide antenna 2364 b; C represents a lesion initiated directly under waveguide antenna 2364 c; D represents a lesion initiated directly under waveguide antenna 2364 d. According to an embodiment of the invention lesions may be created in a predetermined order such as, for example, A-AB-B-BC-C-CD-D where: A represents a lesion initiated directly under waveguide antenna 2364 a; AB represents a lesion initiated under the intersection between waveguide antenna 2364 a and waveguide antenna 2364 b; B represents a lesion initiated directly under waveguide antenna 2364 b; BC represents a lesion initiated under the intersection between waveguide antenna 2364 b and waveguide antenna 2364 c; C represents a lesion initiated directly under waveguide antenna 2364 c; CD represents a lesion initiated under the intersection between waveguide antenna 2364 c and waveguide antenna 2364 d; and D represents a lesion initiated directly under waveguide antenna 2364 d. According to an embodiment of the invention a lesion AB may be created between waveguide antenna 2364 a and waveguide antenna 2364 b, by driving waveguide antenna 2364 a and waveguide antenna 2364 b simultaneously in phase and with a balanced output from each antenna. According to an embodiment of the invention a lesion BC may be created between waveguide antenna 2364 b and waveguide antenna 2364 c, by driving waveguide antenna 2364 b and waveguide antenna 2364 c simultaneously in phase and with a balanced output from each waveguide antenna. According to an embodiment of the invention a lesion CD may be created between waveguide antenna 2364 c and waveguide antenna 2364 d, by driving waveguide antenna 2364 c and waveguide antenna 2364 d simultaneously in phase and with a balanced output from each waveguide antenna.
[0050] FIG. 24 is a treatment template 2483 according to an embodiment of the invention. According to an embodiment of the invention treatment template 2483 may include axilla outline 2497 , anesthesia injection sites 2485 , landmark alignment marks 2497 , device alignment points 2498 and device alignment lines 2499 . According to an embodiment of the invention axilla outline 2497 may be matched to the hair bearing area of a patient to select an appropriate treatment template 2483 . According to an embodiment of the invention anesthesia injection sites 2485 may be used to identify appropriate points in the axilla for the injection of anesthesia. According to an embodiment of the invention landmark alignment marks may be used to align treatment template 2483 to landmarks, such as, for example, tattoos or moles on the axilla. According to an embodiment of the invention device alignment points 2498 may be used in conjunction with alignment features 3352 to properly align medical treatment device 2300 . According to an embodiment of the invention device alignment lines 2499 may be used in conjunction with an outer edge of compliant member 2375 to properly align medical treatment device 2300 . According to an embodiment of the invention treatment template 2384 provides guidance and placement information for medical treatment device 2300 in matrix format.
[0051] According to an embodiment of the invention, a medical device disposable may include: a tissue chamber may have a tissue opening at a distal end and a rigid surface surrounding the tissue opening; an applicator chamber; a flexible bio-barrier at a proximal end of the tissue chamber the flexible bio-barrier separating the tissue chamber and the applicator chamber, a portion of the flexible bio-barrier forming a tissue contacting surface; a compliant member surrounding the tissue opening, the compliant member may have a proximal opening adjacent the tissue opening and a distal opening, wherein the distal opening may be larger than the proximal opening.
[0052] According to an embodiment of the invention the medical device disposable compliant member may be positioned at an angle of approximately fifty-three degrees with respect to the rigid surface. According to an embodiment of the invention the compliant member may include a wall connecting the proximal opening and the distal opening and the wall may be angled approximately fifty-three degrees with respect to the rigid surface. According to an embodiment of the invention the compliant member may further include an outer rim positioned around the distal opening. According to an embodiment of the invention: the outer rim may extend a distance of approximately 0.033 inches from the distal opening; the compliant member may have a height of approximately 0.25 inches; the tissue opening may have a long axis and a short axis, the tissue opening long axis may be approximately 1.875 inches and the tissue opening short axis may be approximately 1.055 inches; the distal opening in the compliant member may have a long axis and a short axis, the distal opening long axis may be approximately 2.429 inches and the distal opening short axis may be approximately 1.609 inches; the tissue contact surface may have a long axis and a short axis, the long axis may be approximately 1.54 inches and the short axis may be approximately 0.700 inches. According to an embodiment of the invention the wall may be substantially straight. According to an embodiment of the invention the compliant member may include one or more alignment marks, at least one of the alignment marks may be positioned on a long side of the compliant member. According to an embodiment of the invention the alignment marks may be positioned on a wall of the skirt and may extend from approximately the rim toward the tissue opening. According to an embodiment of the invention the alignment marks may move with respect to an applicator positioned in the applicator chamber when the medical device disposable is pressed against tissue with sufficient pressure to compress the compliant member. According to an embodiment of the invention the wall may have a thickness of approximately 0.050 inches. According to an embodiment of the invention the tissue chamber may include a chamber wall extending from the tissue opening to approximately the tissue contact surface, the wall may also include a substantially smooth, radiused surface. According to an embodiment of the invention the radiused surface may have a radius of approximately three-sixteenths of an inch. According to an embodiment of the invention the compliant member may have durometer density rating of approximately A60.
[0053] According to an embodiment of the invention, a medical device disposable may include: a tissue chamber including a tissue contact surface at a proximal end of the tissue chamber and a tissue opening at a distal end of the tissue chamber; an applicator chamber; a flexible bio-barrier at a proximal end of the tissue chamber the flexible bio-barrier separating the tissue chamber and the applicator chamber, the flexible bio-barrier forming at least a portion of the tissue contact surface; a vacuum port; a vacuum circuit connecting the tissue chamber, the applicator chamber and the vacuum port, the vacuum circuit including a vacuum passage.
[0054] According to an embodiment of the invention the vacuum circuit may include: a vacuum passage positioned around the tissue contact surface; a vacuum channel positioned around the vacuum passage, the vacuum channel positioned between the vacuum passage and the vacuum port; an applicator bio-barrier positioned between the vacuum port and the applicator chamber, the applicator bio-barrier being substantially permeable to air and substantially impermeable to fluids. According to an embodiment of the invention the vacuum passage may completely surround the tissue interface surface. According to an embodiment of the invention the vacuum passage may substantially surrounds the tissue interface surface. According to an embodiment of the invention the vacuum passage may be positioned in a wall of the tissue chamber adjacent the tissue contact surface. According to an embodiment of the invention vacuum port may be connected to a vacuum tube. According to an embodiment of the invention the vacuum tube may include a generator bio-barrier. According to an embodiment of the invention the generator bio-barrier may be substantially permeable to air and being substantially impermeable to fluids. According to an embodiment of the invention the vacuum channel may include a well region adapted to collect fluids from the tissue chamber. According to an embodiment of the invention a compliant member may surround the tissue opening, the compliant member may have a proximal opening adjacent the tissue opening and a distal opening, wherein the distal opening may be larger than the proximal opening. According to an embodiment of the invention the vacuum passage may be an opening between a wall of the tissue chamber and the tissue bio-barrier. According to an embodiment of the invention the vacuum passage may be approximately 0.020″ inches wide. According to an embodiment of the invention the vacuum passage may be greater than approximately 0.010″ inches when the medical device disposable may be attached to an applicator. According to an embodiment of the invention the tissue surface may have an area greater than an outer area of an antenna array in an applicator affixed to the medical device disposable. According to an embodiment of the invention the tissue surface may have an area greater than an aperture area of an antenna array in an applicator affixed to the medical device disposable.
[0055] According to an embodiment of the invention a method of creating a lesion in skin is described, the method including the steps of: positioning an apparatus including a plurality of antennas adjacent a skin surface; supplying energy to a first antenna at a first power level for a first time period; supplying energy to a second antenna at a second power level for a second time period; supplying energy simultaneously to both the first antenna and the second antenna for a third time period, wherein, during the third time period the energy may be supplied to the first antenna at a third power level and the energy may be supplied to the second antenna at a fourth power level. According to an embodiment of the invention the energy supplied to the first antenna may be in phase with the energy supplied to the second antenna. According to an embodiment of the invention the energy supplied to the first antenna may be phase shifted from the energy supplied to the second antenna. According to an embodiment of the invention the energy supplied to the first antenna may be phase shifted approximately one hundred eighty degrees from the energy supplied to the second antenna. According to an embodiment of the invention the energy supplied to the first antenna may be phase shifted between one and one hundred eighty degrees from the energy supplied to the second antenna. According to an embodiment of the invention the energy output from the first antenna may be substantially in phase with energy output from the second antenna. According to an embodiment of the invention the energy supplied to the first antenna may be phase shifted from the energy supplied to the second antenna, the phase shift being sufficient to cause energy output from the first antenna to be in phase with energy output from the second antenna. According to an embodiment of the invention the energy supplied to the first and second antennas may be microwave energy having a frequency of approximately 5.8 GHz. According to an embodiment of the invention the first and second antennas may be microwave antennas. According to an embodiment of the invention the first and second antennas may be waveguide antennas. According to an embodiment of the invention the first and the second power levels may be substantially equal. According to an embodiment of the invention the first power level may be greater than the second power level. According to an embodiment of the invention the power emitted by the first antenna may be substantially equal to power emitted by the second antenna.
[0056] According to an embodiment of the invention a medical device applicator may include: an antenna array including at least two antenna apertures; at least one intermediate scattering element positioned outside the apertures wherein the at least one intermediate scattering element may be further positioned between the apertures. According to an embodiment of the invention each of the apertures may be substantially rectangular in shape, the apertures including a long axis and a short axis. According to an embodiment of the invention each of the intermediate scattering elements may include a long axis and a short axis wherein the long axis of the at least one intermediate scattering element may be substantially parallel to the long axis of the aperture. According to an embodiment of the invention the medical device applicator may include a cooling plate and the intermediate scattering element may be positioned between the antenna apertures and the cooling plate. According to an embodiment of the invention the medical device applicator may further include one or more coolant chambers positioned between the cooling plate and the antenna aperture. According to an embodiment of the invention the medical device applicator may include at least two central scattering elements positioned under the aperture wherein the at least one intermediate scattering element may be positioned between the central scattering elements. According to an embodiment of the invention the central scattering elements may be positioned substantially in a center of one of the antenna apertures. According to an embodiment of the invention the long axis of the intermediate scattering element may be shorter than the longest dimension of the central scattering element. According to an embodiment of the invention the intermediate scattering element may be manufactured from a material which may have the same dielectric constant as the central scattering element. According to an embodiment of the invention the intermediate scattering element may be made from alumina. According to an embodiment of the invention the intermediate scattering element may be made from a material which may be more than 90 percent alumina. According to an embodiment of the invention the intermediate scattering element may be made from a material which may be approximately 96 percent alumina. According to an embodiment of the invention the intermediate scattering element may be made from, for example silicone. According to an embodiment of the invention one or more temperature measurement devices may be positioned on the cooling plate under the intermediate scattering element. According to an embodiment of the invention the one or more temperature measurement device may be one or more thermocouples.
[0057] According to an embodiment of the invention a medical device applicator may include at least a first and a second waveguide antenna and at least a first electrically conductive shim positioned between the waveguide antennas. According to an embodiment of the invention each of the waveguide antennas may include: a dielectric core having four sides; metal plating on three sides of the dielectric core, the fourth side of the dielectric core forming an antenna aperture. According to an embodiment of the invention the electrically conductive shim may be copper. According to an embodiment of the invention the electrically conductive shim may be approximately 0.025 inches thick. According to an embodiment of the invention the electrically conductive shim may be positioned between the first and second waveguide antennas such that an edge of the electrically conductive shim may be adjacent the antenna apertures. According to an embodiment of the invention an intermediate scattering element may be positioned under the conductive shim. According to an embodiment of the invention central scattering elements may be positioned under the antenna apertures. According to an embodiment of the invention the medical device applicator may include a cooling plate. According to an embodiment of the invention the intermediate scattering element and the central scattering element may be positioned between the antenna apertures and the cooling plate. According to an embodiment of the invention the medical device applicator may include a coolant chamber positioned between the antenna apertures and the cooling plate. According to an embodiment of the invention the medical device applicator may include temperature sensors positioned on the cooling plate.
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The present invention is directed to systems, apparatus, methods and procedures for the noninvasive treatment of tissue, including treatment using microwave energy. In one embodiment of the invention a medical device and associated apparatus and procedures are used to treat dermatological conditions using, for example, microwave energy.
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CROSS-REFERENCE TO RELATED APPLICATIONS
Not Applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
BACKGROUND OF THE INVENTION
1. Field of Invention
This invention relates generally to methods and apparatus for use in the manufacture of vehicle tires. In particular, this invention relates to methods and apparatus for the positioning of a green tire carcass on a shaping drum. More particularly, this invention pertains to
2. Description of the Related Art
In the manufacture of vehicle tires, one process operation includes positioning of a green tire carcass on a shaping drum whereupon the carcass is inflated to a generally desired toroidal shape. The green tire carcass normally is of a generally hollow cylindrical geometry having a non-extensible bead ring secured internally of each of the opposite ends of the carcass. The shaping drum of the prior art includes first and second generally cylindrical mandrels which are disposed on opposite sides of a centerplane oriented perpendicular to the longitudinal centerline of the drum. This longitudinal centerline also defines the rotational axis of the drum. The mandrels of a shaping drum are designed to engage the bead ring-containing opposite ends of the carcass and thereby hold the carcass centered on the drum relative to the centerplane and concentric with respect to the rotational axis of the drum.
In the present embodiment, each of the mandrels is of the radially expansible type, that is, each mandrel comprises a plurality of segments which are disposed radially about the rotational axis of the drum and which collectively define generally the outer circumference of an annular receiver for one of the bead rings of the carcass. The segments of each mandrel are radially moveable relative to the rotational axis of the drum for locking the bead rings of the carcass to the drum and are laterally movable to permit initial selection of the spacing between the bead rings as the carcass. and adjustment of their lateral spacing as the carcass is radially expanded to define a green tire.
For proper functioning of the shaping drum and true rotational dimensioning of the carcass into a vehicle tire, it is important that the carcass initially be positioned precisely centrally of the shaping drum both radially of the drum and laterally of the centerplane of the drum so that upon inflation of the carcass toward a toroidal geometry, all parts of the carcass move or expand uniformly with respect to one another, thereby ensuring uniformity of symmetry of the expanded carcass, as well as uniformity of distribution of the material of construction of the carcass, and ultimately, uniformity of the radial and lateral dimensions and material distribution of the finished tire.
A typical green tire carcass for an automobile will weigh 35-50 pounds or more and is relatively flimsy. Obviously, a green carcass for a truck tire, or an off-the-road (OTR) tire, will be considerably heavier and more difficult to manipulate. Accordingly, loading of the carcass onto a shaping drum is difficult in several aspects. For example, manually placing the carcass onto the drum from one end of the drum, that is “threading” of the carcass initially onto one end of the drum and further moving the carcass toward the lateral centerplane of the drum is difficult in that the carcass tends to bend, twist, collapse and/or sag due to gravity, from its open cylindrical geometry when lifted by an operator or a mechanical transfer device. After the carcass has been initially threaded onto the drum, there remains the problem of completing the centering the carcass relative to the lateral centerplane of the drum so that the bead rings are disposed on opposite sides of, and equidistantly from the centerplane of the drum and equidistant radially about the rotational axis of the drum. These and other positioning efforts are frustrated by the tendency of the carcass to “sag” under the effects of gravity thereby impeding the radial centering of the carcass relative to the longitudinal centerline of the drum before, or as, the bead rings become locked to the mandrels of the drum. Failure to center the carcass both radially and longitudinally of the shaping drum can result in non-uniform distribution of the material of the carcass, hence of the finished tire, with the result that the finished tire is unacceptably “out of round” and must be scrapped.
BRIEF SUMMARY OF THE INVENTION
In accordance with one aspect of the present invention there is provided improved means for centering of a green tire carcass on a shaping drum. “Centering” as used herein and unless otherwise stated or obvious from the context of its use, includes positioning of the bead ring-containing opposite ends of a carcass substantially equidistantly from the centerplane of the drum and substantially radially equidistant from, and substantially concentric about, the rotational axis of the drum. In one embodiment, the shaping drum includes first and second pluralities of lateral positioning shoes disposed about the outer circumference of the drum, these pluralities of shoes being disposed on opposite sides of the lateral centerplane of the drum, and first and second pluralities of bidirectional (radial and lateral) positioning wheels, the pluralities of wheels also being disposed about the outer circumference of the drum, on opposite sides of the lateral centerplane of the drum, and between respective ones of the pluralities of shoes and the lateral centerplane of the drum. These shoes and wheels are selectively positionable laterally and radially of the drum.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a representation of a shaping drum embodying various of the features of the present invention;
FIG. 2 is an end view of the drum depicted in FIG. 1;
FIG. 3 is a side elevation view, in section, of the drum depicted in FIG. 1;
FIG. 4 is a representation of a drum in accordance with the present invention and depicting the opposite sections of the drum in their spaced apart relationship and with the carcass positioning shoes and wheels disposed in their radially retracted positions;
FIG. 5 is a representation of the drum depicted in FIG. 4 with the positioning shoes and wheels disposed in their radially extended positions;
FIG. 6 is a representation of a portion of the right-hand section of the drum depicted in FIG. 4 and depicting spatial and functional relationships of the carcass positioning shoes and wheels employed in one embodiment of the present invention;
FIG. 7 is a further representation of a further portion of the right-hand section of the drum depicted in FIG. 4 and depicting further details of drum;
FIG. 8 is a side elevation view of a drum embodying various of the features of the present invention and depicting a green tire carcass encircling the drum;
FIG. 9 is a detail view of a portion of the drum depicted in FIG. 8 and taken generally along the line 8 — 8 of FIG. 7;
FIG. 10 is a side elevation view of the inboard section of a drum of the type depicted in FIG. 4 and showing the multidirectional wheels in their retracted positions;
FIG. 11 is an end view of the drum section depicted in FIG. 10;
FIG. 12 is a side elevation view of the inboard section of a drum of the type depicted in FIG. 4 and showing the multidirectional wheels in their extended positions;
FIG. 13 is an end view of the drum section depicted in FIG. 12;
FIG. 14 is a representation of a mounting arm for a positioning wheel of the present invention;
FIG. 15 is a representation of a mounting lug for the base end of the cylinder of a piston/cylinder actuating device for effecting radial movement of the shoes/wheels of the present invention;
FIG. 16 is a representation of a lever arm for interconnecting the outboard end of a piston rod of a piston/cylinder actuation device with a driven gear ring employed in one embodiment of the present invention.
FIG. 17 is a representation of an alternative embodiment of a positioning shoe as employed in the present invention; and
FIG. 18 is a further representation of the positioning shoe depicted in FIG. 17 .
DETAILED DESCRIPTION OF THE INVENTION
Referring initially to FIGS. 1-3, in the depicted embodiment of the drum 10 of the present invention, there is provided a central (rotational) shaft 12 having a radial shoulder 14 suitable for attachment of the depicted drum to a conventional drive system for a shaping drum. The depicted drum includes a rotational axis 16 and a centerplane 18 (see FIG. 4 ). The drum is divided into substantially a first (inboard) section 20 and a second (outboard) section 22 , each section being mounted on the shaft 12 for simultaneous rotation of the sections upon rotation of the shaft 12 . Further, each section is translatable laterally of the centerplane of the drum, the two sections moving substantially simultaneously toward the centerline or substantially simultaneously away from the centerline. Common or equivalent components of the two sections of the drum are designated using primed numerals.
Referring specifically to FIG. 3, in the depicted drum, internally of the shaft 12 there is provided a lead screw 23 having one of its opposite ends 24 rotatably mounted in the inboard end of the shaft 12 and its opposite (outboard) end 25 rotatably mounted internally of the outboard section 22 of the drum. The inboard end 24 of the lead screw projects laterally outwardly of the drum to define a lug 26 by means of which the lead screw may be rotated relative to the shaft 12 .
Adjacent the inboard end of the lead screw, there is provided a lead nut 30 which threadably encircles the lead screw and whose outer circumference is secured to the inboard end 32 of a first hollow cylindrical tube 34 so that upon rotation of the lead screw, the lead nut and its attached tube 34 move inwardly or outwardly relative to the shaft 12 , depending upon the direction of rotation of the lead screw. Adjacent the outboard end 36 of the tube 34 , there is provided a second lead nut 38 which threadably encircles the outboard end 25 of the lead screw and which has its outer circumference attached to mounting lugs 40 , 41 which, in turn, are attached to the inboard section 20 of the drum at diametrically opposite locations about the shaft 12 . Further, the outboard end 36 of the tube 34 is attached by a mounting ring 42 to the outboard section 22 of the drum. Thus, it will be seen that rotation of the lead screw effects lateral movement of the two halves 20 , 22 of the drum relative to each other. By design, rotation of the lead screw effects about twice as much lateral movement of the inboard drum section 20 as the lateral movement of the outboard section 22 of the drum. To accommodate this relative movement between the drum halves, the tube 34 is provided with a slot 44 which extends substantially from end to end of the tube 34 and the shaft 12 within which the tube is slidably mounted, is provided with a slot 46 which extends from proximate the outboard end of the shaft 12 to a point about midway along the length of the shaft 12 . These slots are in register and the mounting lugs 40 , 41 reside in and slide along these registered slots. This construction provides for lateral movement of the drum halves relative to one another, without rotational movement of either section relative to the shaft 12 or the tube 34 . By this means, all of the components of each of the two sections 20 , 22 are translatable laterally relative to the centerplane 18 of the drum.
As depicted in the several Figures, in the depicted embodiment, each of the inboard and outboard drum sections 20 , 22 , includes a carcass alignment subassembly 50 , 52 , these assemblies being substantially mirror images of one another.
Referring specifically to the inboard section 20 of the drum depicted in FIGS. 4, 5 and 9 , the carcass alignment subassembly 50 includes a first plurality of positioning wheels 52 disposed about the outer circumference of the inboard section of the drum, and adjacent to the transverse centerplane 18 of the drum. Each positioning wheel 52 is provided with a plurality of barrel-type rollers 54 disposed at spaced apart locations about the outer circumference of the wheel. In one embodiment (see FIGS. 6 and 9 ), each of these rollers 54 is mounted within a depression 56 in the outer circumference 58 of its respective wheel for rotation about a rotational axis 60 that is aligned substantially parallel to a chord of the outer circumference of the wheel. As depicted, (see also FIGS. 5 and 14) each wheel is mounted between the legs 62 and 64 of a rocker arm 66 whose opposite end 68 is pivotally mounted, by a pin 69 , to a cylindrical hub 71 which is mounted nonrotatably, but laterally slidably relative to the shaft 12 . The axis of rotation 57 of the wheel 52 is disposed perpendicular to the axes of rotation of its respective rollers 54 .
Referring also to FIG. 9, the carcass alignment subassembly 50 further includes a first plurality of lateral alignment shoes 72 also disposed about the outer circumference of the drum and immediately inboard of the first plurality of positioning wheels 52 . Each lateral positioning shoe 60 comprises a generally arcuate, i.e., curved, body portion 74 including an outer surface 75 which defines a portion of an outer circumference of the drum. That edge 76 of the shoe disposed nearest the centerplane of the drum is provided with a bifurcated projection 78 which extends radially inwardly of the drum, terminating as legs 83 , 84 , and receives therein a shaft 80 which is oriented substantially parallel to the rotational axis of the drum, and about which the shoe is pivotable. The opposite end 82 of the shoe projects in cantilevered fashion laterally outwardly of the drum from the bifurcated projection, and terminates in the form of a radially inwardly curved distal surface 84 . As depicted in FIG. 9, each shoe is provided with a channel 85 which extends between opposite sides of the shoe and which opens outwardly of the surface 75 of the shoe. As depicted in FIGS. 7 and 13, for example, the shoes of each section of the drum are encircled by an elastic band 87 which resides in the channels of the several shoes of each section of the drum. By this means, the rotational movement of the shoes is restricted to a few degrees of rotation, thereby maintaining the orientation of the outer surface of each shoe generally concentric with respect to the outer circumference of the drum, but allowing a relatively small degree of freedom of rotation to provide for alignment of each shoe such that its distal edge properly engages the inner circumference of the carcass adjacent a respective bead ring. This elastic band is not shown in most of the drawings for purposes of clarity.
In one embodiment of the present invention (see FIG. 9 ), the positioning wheels 52 of the first plurality of positioning wheels and the lateral positioning shoes of the first plurality of positioning shoes are disposed in pairs, a pair comprising one wheel 52 and one shoe 72 . In this embodiment, the wheel and shoe of each pair are rotatably/pivotally mounted on a common axis, which may comprise the common shaft 80 that is mounted between the bifurcated outboard legs 86 , 88 of a rocker arm 90 and which also extends to be received between the arms 82 , 84 of the bifurcated projection 76 of the shoe 72 . The axis of this shaft 80 which mounts the wheel and shoe of each pair is disposed substantially parallel to the rotational axis 16 of the drum. In this embodiment, this common mounting of the positioning wheels and shoes is repeated in mirror image fashion on the opposite side of the centerplane of the drum with a second plurality of positioning wheels 52 ′ and a second plurality of positioning shoes 60 ′ associated with the outboard section of the drum.
As may been seen in FIGS. 4, 7 and 9 , in the depicted embodiment of the present invention, the physical mounting of each shoe relative to its associated wheel, when employing a combination of wheels and shoes, provides for the arcuate radially outer surface 75 of each shoe to be disposed more radially inwardly of the drum relative to the outer circumference 58 of each wheel. This mounting relationship of the shoes and wheels provides for the inner circumference 108 or a carcass 110 which is initially threaded onto the drum to engage, and be supported by, the rollers in the outer circumference of each wheel with the inner circumference of the carcass spaced apart from the outer surface 75 of each shoe. This spacing of the carcass away from the outer surface of the shoes permits the carcass to be moved readily laterally of the drum and/or rotated about the rotational axis of the drum without impedance from the outer surfaces of the several shoes.
Referring to FIGS. 5, 6 , 7 and 9 , on a given side of the centerplane 18 of the drum, that end of each rocker arm 90 opposite its bifurcated end is provided with gear teeth 100 which mesh with like gear teeth 102 provided in the radially outward circumferential surface 104 of a driven gear ring 106 which is free-floating rotatably mounted on the outer circumference of the cylindrical hub 71 and adjacent the annular mounting ring 70 . By this means, each of the rocker arms for each of the pairs of shoes and wheels is mechanically interconnected to every other of the rocker arms on a given side the centerplane of the drum so that upon rotation of the driven gear ring 106 , all of the rocker arms pivot simultaneously in the same direction and by the same amount.
Referring to FIGS. 9-13, as so operably disposed, each of the positioning shoes 72 and each wheel 52 may be pivoted between a first (extended) position in which the outer surface of each shoe and the outer circumference of each wheel of each pair of shoes and wheels projects radially beyond the general outer overall circumference of the drum, and a second (retracted) position in which each pair of shoes and wheels is disposed radially inwardly of the general outer overall circumference of the drum. As noted, in their first positions (during carcass loading), the outer surface of the shoe is more radially inward of the drum than are the rollers of its respective wheel by a distance, e.g. about 2 inch, sufficient to create a space 77 between the outer surface 75 of each shoe and the internal cylindrical circumference 108 of a carcass 110 disposed on the drum 10 , while at the same time positioning the radially inwardly extending edge 82 of each shoe to engage the carcass at a location adjacent a bead ring 112 disposed within an end 114 of the carcass.
Rotation of the driven gear ring is provided for by means of at least one, and in one embodiment, a plurality of piston/cylinder devices 116 operably interconnected between the fixed annular mounting ring 70 to which the rocker arms 90 are pivotally mounted, and one or more of the lever arms 118 (see FIGS. 6 - 9 ). In the depicted embodiment, each of the lever arms 118 includes a bifurcated end 120 between the legs of which the end 122 of a piston/cylinder rod 121 is pivotally pinned 123 , and a distal end 124 which is provided with a plurality of gear teeth 126 which mesh with like gear teeth 1102 on the driven gear ring 106 . Each lever arm is pivotally mounted, intermediate its opposite ends to the inner surface 67 of the annular mounting ring 70 as by a pin 128 . The base end 130 of the cylinder of each piston/cylinder device is pivotally anchored to the outer circumference of the annular mounting ring 70 as by a mounting bracket 132 which is pinned 133 at one end 134 thereof to the inner surface 108 of the annular mounting ring 70 and whose opposite end includes a yoke 136 to which the base end of the cylinder is pinned.
Upon rotation of the driven gear ring 106 relative to the mounting ring 70 by means of actuation of the piston/cylinder devices(s) 116 , each of the pairs of shoes and wheels on a given side of the centerline of the drum are caused to pivot either radially outwardly or radially inwardly relative to the rotational axis of the drum and thereby present the shoes and wheels for engagement therewith by the inner circumferential surface 108 of a carcass 110 being loaded onto the shaping drum, or to withdraw the shoes and wheels from engagement with the inner surface of such carcass.
Rotation of the driven gear ring 106 ′ on the opposite side of the centerline of the drum is effected substantially identically as described. In one embodiment, the piston/cylinder devices 116 , 116 ′ disposed on the opposite sides of the centerplane are connected to a common source of hydraulic or pneumatic fluid and are controlled to function simultaneously and in like manner so that the wheels and shoes on both sides of the centerline of the drum move simultaneously and in like radial direction and extent of movement as do the wheels and shoes disposed on the opposite side of the centerline of the drum.
In accordance with one embodiment of the method of the present invention, in preparation of the shaping drum for the threading of a carcass thereon, the piston/cylinder devices are actuated to rotate the driven gear rings, causing each pair of the shoes and wheels to simultaneously pivot about their respective pivot axes in a direction toward their retracted positions radially inwardly of the drum. This position of the shoes and wheels is depicted in FIGS. 10 and 11 and provides for the passage of the bead ring-containing ends 114 , 114 ′ past the wheels and shoes on respective outboard and inboard sections of the drum. Thereupon, the green tire carcass (see FIG. 8) is initially threaded onto the outboard end of the drum and into a position where each of its opposite ends is disposed generally in encircling relationship to a respective plurality of pairs of wheels and shoes.
Once the carcass has been manually threaded onto the drum to the extent that the bead rings 112 , 112 ′ at the opposite ends 114 , 114 ′ of the carcass (see FIGS. 7 and 8 ), are disposed laterally beyond the distal ends 84 , 84 ′ of the shoes of each of the first and second sections of the drum, radial movement of the wheels and shoes outwardly of the drum is commenced. As the outer surface of the rollers in the outer circumference of each wheel engage the inner circumference of the carcass, a radially directed pressure is exerted against the inner circumference of the carcass causing the carcass to be formed into a substantially uniform cylinder intermediate the bead rings in the opposite ends of the carcass.
Substantially simultaneously with the action of “rounding up” of the carcass and the slight laterally inward movements of the bead rings, the distal curved ends of the shoes on opposite sides of the centerplane engage the inner circumference of the carcass at locations laterally inwardly of their respective bead rings in the opposite ends of the carcass. The radially outward movement of these curved ends of the shoes against the inner circumference of the carcass develops a resultant vectorial force acting against each end of the carcass adjacent each bead ring, but in opposite directions laterally from the centerplane of the drum. Because the uniformly cylindrical carcass is supported on the rollers of the wheels, and each wheel is freely rotatable about an axis parallel to the shaft of the drum, the carcass is in position to be readily moved laterally of the drum in either direction so that the vectorial forces exerted against the inner circumference of the carcass move the carcass to a position wherein the bead rings are disposed substantially equidistantly from the centerplane of the drum. This action occurs very rapidly (on the order of 2-3 seconds) and once completed, the bead rings of the carcass are in position to be locked into engagement with the drum and the carcass expanded to define a tire, and/or for other operational processes to be performed thereon. When the formed tire is ready to be removed from the shaping drum, the driven gear rings are rotated to cause the wheels and shoes to retract to their retracted position radially inwardly of the drum so that the formed tire may be readily removed from the shaping drum.
The construction and actuation of the bead ring clamps indicated generally by the numerals 150 and 150 ′ (FIGS. 3, 8 and 9 ), may be of a design known in the art. The present bead ring clamping mechanism associated with each section of the drum includes a plurality of arms 160 , each of which is individually pivotably mounted at one end 162 thereof, and each of which carries a bead ring clamp 164 on its opposite end 166 . Actuation of the arms is by means of pressurized fluid introduced into a cylindrical chamber 168 to cause a cylinder 170 to move laterally of the drum and urge rollers 172 associated with the arms 160 toward engagement with a ramping surface 174 on each arm 160 and thereby urge the ends 166 of the arms 160 , and their respective bead clamps radially of the drum to engage the bead rings. This mechanism is duplicated for the other section of the drum, and preferably, their respective actuations are coordinated to produce substantially simultaneous movement of the bead clamps. In FIGS. 5 and 6 there is depicted an elastomeric cylindrical covering 175 for the proximal ends of the bead locks. This covering is useful for protecting the proximal ends of the bead locks against contaminants, etc. and is omitted from others of the drawings for purposes of clarity.
As is true with known shaping drums, once the bead rings of the carcass have been locked to the drum, the carcass is inflated to expand the carcass into the desired toroidal shape. This action requires that the locked bead rings move simultaneously and equally inward of the drum toward the centerline of the drum. This action is accomplished through the means of the lead screw 23 , its lead nuts 30 and their interconnection with the sections 20 , 22 of the drum. This structure, and its operation, are well known in the art.
In one embodiment, the gear teeth provided on the outer circumference of the driven gear ring are present only adjacent each of the inboard ends of the rocker arms, as opposed to gear teeth about the entire circumference of the driven ring. Other modifications and/or equivalents of the disclosed embodiments of the present invention will be recognized by one skilled in the art and it is intended that the invention be limited only as set forth in the claims appended hereto.
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In accordance with one aspect of the present invention there is provided improved means for centering of a green vehicle tire carcass on a shaping drum. “Centering” as used herein and unless otherwise stated or obvious from the context of its use, includes positioning of the bead ring-containing. opposite ends of a carcass substantially equidistantly from the centerplane of the drum and substantially radially equidistant from, and substantially concentric about, the rotational axis of the drum. In one embodiment, the shaping drum includes first and second pluralities of lateral positioning shoes disposed about the outer circumference of thedrum, these pluralities of shoes being disposed on opposite sides of the lateral centerplane of the drum, and first and second pluralities of bidirectional (radial and lateral) positioning wheels, the pluralities of wheels also being disposed about the outer circumference of the drum, on opposite sides of the lateral centerplane of the drum, and between respective ones of the pluralities of shoes and the lateral centerplane of the drum. These shoes and wheels are selectively positionable laterally and radially of the drum to effect centering of the carcass. A method is disclosed.
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GOVERNMENT SPONSORSHIP
Work relating to this invention was partially supported by a contract from the National Institutes of Health, Contract/Grant No. 5 R01 HL24 036-02.
This is a divisional of co-pending application Ser. No. 003,178, filed on Jan. 12, 1987, now U.S. Pat. No. 4,787,900, which is a continuation of Ser. No. 369,614, filed on Apr. 19, 1982, now abandoned.
BACKGROUND OF THE INVENTION
It is widely acknowledged that the use of autologous vascular tissue in repair or replacement surgical procedures involving blood vessels, especially small blood vessels (i.e., 5 mm or less) provides long-term patency superior to that of commercially available prostheses. However, the use of autologous vascular grafts (eg. autologous vein grafts used in coronary bypass surgery) is associated with several problems. For example, harvesting of an autologous vascular graft constitutes a serious surgical invasion which occasionally leads to complications. Furthermore, the autologous vascular graft may frequently be unavailable due to specific morphological or pathophysiological characteristics of the individual patient. For example, a patient may lack a length of vein of the appropriate caliber or an existing disease (eg. varicose veins) may result in veins of unsuitable mechanical compliance. In addition to the foregoing, the use of autologous vein grafts for coronary bypass or femoropopliteal bypass or for interposed grafting of arteries frequently leads to development of intimal proliferation which eventually leads to loss of patency.
The experience with autologous vein grafts suggests the need for a suturable tubular product available without invading the patient. This product should be readily available in sterile form and in a large variety of calibers, degrees of taper of internal diameter and degrees of bifurcation (branching). In addition to ready availability and long-term patency, the graft should also remain free of aneurysms, infection and calcification and should not cause formation of emboli nor injure the components of blood over the duration of anticipated use.
The present invention is a blood vessel prosthesis which meets all of the foregoing criteria.
SUMMARY OF THE INVENTION
A blood vessel prosthesis in accordance with the present invention is a multilayer tubular structure with each layer being formed from a bioreplaceable material that is capable of being prepared in the form of a strong, suturable tubular conduit of complex geometry. This bioreplaceable material can be either a natural or a synthetic polymer. The preferred natural material is collagen-aminopolysaccharide. The preferred synthetic material is a polymer of hydroxyacetic acid. Adjacent layers can be prepared by use of different polymers giving a multilayered composite tubular structure.
The material of the blood vessel prosthesis is capable of undergoing biodegradation in a controlled fashion and replacement, without incidence of cellular proliferative processes, synthesis of fibrotic tissue or calcification. The use of the prosthesis of the present invention enables regeneration of the transected vascular wall of the host, thereby obviating long-term complications due to the presence of an artificial prosthesis. Of course, the material of the blood vessel is compatible with blood and does not cause platelet aggregation or activation of critical steps of the intrinsic and extrinsic coagulation cascades.
The multilayer tubular structure in accordance with the present invention possesses mechanical strength sufficient for convenient suturing and for withstanding without rupture the cyclical load pattern imposed on it by the cardiovascular system of which it forms a part. Its mechanical compliance matches the compliance of the blood vessel to which the graft is sutured, thereby minimizing thrombus formation caused by a geometric discontinuity (expansion or contraction of conduit). The prosthesis has sufficiently low porosity at the bloodgraft interface to prevent substantial leaking of whole blood or blood components. The blood compatibility is sufficient to prevent thrombosis or injury to blood components or generation of emboli over the period of time during which the graft is being replaced by regenerating vascular tissue.
The prosthesis has the property of replacing the vital functions of blood vessel both over a short-term period, up to about 4 weeks, in its intact or quasi-intact form; as well as the property of replacing the functions of a blood vessel over a long-term period, in excess of about 4 weeks, in its regenerated form, following a process of biological self-disposal and replacement by regenerating vascular tissue of the host. The long term function of the prosthesis is related to its ability to act as a tissue regeneration template, a biological mold which guides adjacent tissue of the blood vessel wall to regrow the segment which was removed by surgery. The term bioreplaceable refers to this process of biological self-disposal and replacement by regeneration.
Accordingly an object of the invention is to provide a blood vessel prosthesis which possesses many of the advantages of autologous vascular tissue and which can be used in place of autologous vascular grafts to eliminate many of the problems associated with their use.
A further object of the invention is to provide a process for making such a blood vessel prosthesis.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of a blood vessel prosthesis in accordance with the present invention;
FIG. 2 is a diagrammatic illustration of the process of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
At the outset the invention is described in its broadest overall aspects with a more detailed description following. As is shown in FIG. 1, the blood vessel prosthesis 10 of the present invention is, in one important embodiment, a multilayer tubular structure consisting of an inner tubular layer 12 comprising a relatively smooth and non-porous bioreplaceable polymeric lining, optionally seeded with endothelial, smooth muscle or fibroblast cells prior to grafting, and which serves as a scaffold for neointimal and neomedial tissue generation; and, an outer tubular layer 14 comprising a tough and highly porous bioreplaceable polymeric layer optionally seeded with smooth muscle or fibroblast cells prior to grafting and which serves as a scaffold for neoadventitial and neomedial tissue generation and mechanical attachment of the graft to the host's perivascular tissues.
Following the complete disposal of the graft by biodegradation and its replacement by neovascular tissue without incidence of cellular proliferative processes, the newly formed blood vessel possesses the histological structure of the physiological blood vessel wall.
The preferred materials for the prosthesis of the present invention are cross-linked collagen-aminopolysaccharide composite materials disclosed in U.S. Pat. No. 4,280,954 by Yannas et al., the teachings of which are incorporated herein by reference.
These composite materials have a balance of mechanical, chemical and physiological properties which make them useful in surgical sutures and prostheses of controlled biodegradability (resorption) and controlled ability to prevent development of a foreign body reaction, and many are also useful in applications in which blood compatibility is required. Such materials are formed by inti:nately contacting collagen with an aminopolysaccharide under conditions at which they form a reaction product and subsequently covalently cross-linking the reaction product
The products of such syntheses are collagen molecules or collagen fibrils with long aminopolysaccharide chains attached to them. Covalent cross-linking anchors the aminopolysaccharide chains to the collagen so that a significant residual quantity of aminopolysaccharide remains permanently bound to collagen even after washing in strong aminopolysaccharide solvents for several weeks.
Collagen can be reacted with an aminopolysaccharide in aqueous acidic solutions. Suitable collagen can be derived from a number of animal sources, either in the form of a solid powder or in the form of a dispersion, and suitable aminopolysaccharides include, but are not limited to chondroitin 4-sulfate chondroitin 6-sulfate, heparan sulfate dermatan sulfate, keratan sulfate, heparin, hyaluronic acid or chitosan. These reactions can be carried out at room temperature. Typically, small amounts of collagen, such as 0.3% by weight, are dispersed in a dilute acetic acid solution and thoroughly agitated. The polysaccharide is then slowly added, for example dropwise, into the aqueous collagen dispersion, which causes the coprecipitation of collagen and aminopolysaccharide. The coprecipitate is a tangled mass of collagen fibrils coated with aminopolysaccharide which somewhat resembles a tangled ball of yarn. This tangled mass of fibers can be homogenized to form a homogeneous dispersion of fine fibers and then filtered or extruded and dried.
The conditions for maximum attachment of aminopolysaccharide without significant partial denaturation (gelatinization) has been found to be a pH of about 3 and a temperature of about 37° C. Although these conditions are preferred, other reaction conditions which result in a significant reaction between collagen and aminopolysaccharide are also suitable.
Collagen and aminopolysaccharides can be reacted in many ways. The essential requirement is that the two materials be intimately contacted under conditions which allow the aminopolysaccharides to attach to the collagen chains. The collagen-aminopolysaccharide product prepared as described above can be formed into sheets, films, tubes and other shapes or articles for its ultimate application. In accordance with the present invention the collagen-aminopolysaccharide product is formed into tubes and thereafter is cross-linked.
Although the natural collagen-aminopolysaccharide polymer is the preferred material of the invention, other biodegradable and bioreplaceable materials, both natural and synthetic can be used. An example of a synthetic material useful in the invention is a polymer of hydroxacetic acid. Polyhydroxyacetic ester has suitable mechanical properties. Although polyhydroxyacetic ester eventually undergoes complete biodegradation when implanted, its short term strength makes it quite useful as a prosthetic device material.
One method for forming the inner conduit 12 is the cross-flow filtration molding process disclosed in U.S. Pat. No. 4,252,759 entitled "Cross Flow Filtration Molding Method", by Yannas, et al, the teachings of which are incorporated herein by reference. The molding apparatus includes a mold with porous walls having the predetermined shape. The porous walls contain pores having a size sufficient to retain dispersed particles on the wall surface as liquid medium passes through the walls. Means for introducing dispersion to the mold are also present, and typically comprise a pump for pumping dispersion through the mold. Means for applying hydrostatic pressure to dispersion in the porous mold are also part of the apparatus. Typically, such means for applying pressure might be a source of compressed gas attached to a reservoir for the dispersion. The reservoir and a flow development module to eliminate hydrodynamic end effects in the mold are optionally employed.
The cross flow filtration molding process comprises pumping a dispersion of particles through a mold having porous walls which allow transport of a portion of the dispersion medium therethrough. Hydrostatic pressure is applied to drive dispersion medium through the porous mold walls thereby causing particles to deposit on the mold walls to form an article having the predetermined shape. After sufficient particles have deposited to provide the shaped article with the wall thicknesses desired, the flow of dispersion through the mold is halted. If the dispersion used is the preferred collagen-aminopolysaccharide, the shaped article is cross-linked to provide it with significantly improved structural integrity.
The amount of hydrostatic pressure necessary to drive the dispersion through the porous mold walls will vary with many factors, including the chemical composition size, charge and concentration of particles; the chemical composition of the liquid medium; the shape, size, wall thickness, etc., of the article to be molded; and the size of pores in the mold walls. In the case of a dispersion of coprecipitated collagenaminopolysaccharide particles, for example, the pressure applied should be at least about ten p.s.i.g. to achieve a practical rate of medium transport through the mold walls. With larger particles, lower pressures can be used. Also, the desired pressure difference across the mold wall can be established by applying vacuum to the mold exterior.
The wall thickness of the tube produced in the mold can be varied. This is primarily done by adjusting the molding time, but other factors such as the dispersion flow rate, the hydrostatic pressure applied, the dispersion concentration, etc. also affect wall thickness. In accordance with the present invention the wall thickness of inner tube 12 is between the range of 0.1 to 5.0 mm.
It is clear, of course, that a wide variety of mold shapes besides hollow tubing could be employed. In fact, it is believed that the mold could be virtually any closed shape which has at least two ports. Thus, the mold might have the shape of an elbow, T-joint, bifurcated tubes, tubes with tapering diameters, or other shape. The fact that the mold can be virtually any shape is particularly beneficial since a great variety of morphology is found in natural blood vessels.
The incorporation of a woven or knitted fabric, e.g. a polyester velour or mesh, within the prosthesis of the invention serves to mechanically reinforce the prosthesis. One way to incorporate such a fabric within the prosthesis is to line the cross flow filtration mold with the fabric before pumping the dispersion of bioreplaceable particles through the mold.
Another method for forming a collagen-aminopolysaccharide inner conduit 12 is the wet extrusion molding process. In this process a collagen dispersion is extruded through a die over a mandrel into a precipitating aminopolysaccharide bath.
The preferred conditions for producing the collagen tubes by the wet extrusion process are a collagen concentration of 2.5% and a pressure of 12 p.s.i.g. for extrusion. Thickerwalled tubes may be produced uniformly at slightly higher collagen concentrations and extrusion pressures.
The wet extrusion molding process is suitable for fast production of the inner conduit but currently appears limited to fabrication of articles with axial symmetry, i.e., tubes, fibers or sheets. The cross flow filtration molding process, on the other hand, is relatively slow but is suitable for molding of hollow articles of narrow shapes, including bifurcated tubes and tubes with tapering diameters.
As seen in FIG. 2, after the initial formation of the preferred collagen-aminopolysaccharide inner conduit by either the wet extrusion method or the cross flow filtration method, it is cross-linked. If the inner conduit is formed from a synthetic bioreplaceable material, e.g., a polymer of hydroxyacetic acid, there is no cross-linking step, as the material degrades by hydrolysis. Covalent cross-linking can be achieved by many specific techniques with the general categories being chemical, radiation and dehydrothermal methods. An advantage to most cross-linking techniques contemplated, including glutaraldehyde cross-linking and dehydrothermal cross-linking, is that they also serve in removing bacterial growths from the materials. Thus, the composites are being sterilized at the same time that they are cross-linked.
One suitable chemical method for covalently cross-linking the collagen-aminopolysaccharide composite is known as aldehyde cross-linking. In this process the inner tube 12 is contacted with aqueous solutions of aldehyde, which serve to cross-link the materials. Suitable aldehydes include formaldehyde, glutaraldehyde and glyoxal. The preferred aldehyde is glutaraldehyde because it yields the desired level of cross-link density more rapidly than other aldehydes and is also capable of increasing the cross-link density to a relatively high level. It has been noted that immersing the preferred collagen-aminopolysaccharide composites in aldehyde solutions causes partial removal of the polysaccharide component by dissolution thereby lessening the amount of aminopolysaccharide in the final product.
Covalent cross-linking of the preferred collagen-aminopolysaccharide inner conduit serves to prevent dissolution of aminopolysaccharide in aqueous solutions thereby making inner tube 12 useful for surgical prostheses. Covalent cross-linking also serves another important function by contributing to raising the resistance to enzymatic resorption of these materials. The exact mechanism by which crosslinking increases the resistance to enzymatic degradation is not entirely clear. It is possible that cross-linking anchors the aminopolysaccharide units to sites on the collagen chain which would normally be attacked by collagenase. Another possible explanation is that crosslinking tightens up the network of collagen fibers and physically restricts the diffusion of enzymes capable of degrading collagen.
The mechanical properties of collagen-aminopolysaccharide networks are generally improved by crosslinking. Typically, the fracture stress and elongation to break are increased following a moderate crosslinking treatment. Maximal increases in fracture stress and elongation to break are attained if the molded tube is air dried to a moisture content o about 10%-wt. prior to immersion in an aqueous aldehyde crosslinking bath.
In accordance with the present invention, the crosslinked inner conduit 12 should have an M C (number average molecular weight between cross-links) of between about 2,000 to 12,000
Materials with M C values below about 2,000 or above about 12,000 suffer significant losses in their mechanical properties while also undergoing bioreplacement at a rate which is either too slow (low M C ) or a rate which is too fast (high M C ). Composites with an M C of between about 5,000 and about 10,000 appear to have the best balance of mechanical properties and of bioreplacement rate and so this is the preferred range of cross-linking for the inner conduit 12. Such properties must include low porosity (average pore diameter less than 10 microns). Thus the inner conduit should be permeable to low molecular weight constituents of blood, but should not allow leakage of whole blood.
If the inner conduit 12 is formed by cross flow filtration molding, a mandrel is inserted into the lumen of inner conduit 12 and is used to immerse conduit 12 into an aldehyde solution. The above described procedure of forming the inner tube by the cross flow filtration method and thereafter cross linking the tube itself may be repeated to build up an inner tube having a wall thickness of 0.1 to 5.0 mm. If the inner conduit 12 is formed by wet extrusion molding, the mandrel which is already situated in the lumen of inner conduit 12 is used to immerse conduit 12 into an aldehyde solution.
As seen in FIG. 2, after the desired wall thickness is achieved, the inner tube 12 is treated to provide it with outer layer 14, having a thickness of at least 1.0 mm. As has been set forth above, the outer layer 14 is also formed from bioreplaceable materials, preferably collagen-aminopolysaccharides. The outer layer 14 is applied to the inner layer 12 by a freeze drying process. In its broadest overall aspects, this process is performed by immersing the cross linked inner tube 12 in a pan 22 containing the appropriate bioreplaceable polymeric dispersion. As is shown in FIG. 2, the inner tub 12 is supported on a mandrel 38 and the inner tube 12 is covered with the dispersion 17 to form the outer layer of bioreplaceable material. The pan 22 itself is placed on the shelf of a freeze dryer which is maintained at -20° C. or lower by mechanical refrigeration or other methods known to the art. Soon after making contact with the cold shelf surface, the bioreplaceable polymer dispersion freezes and the ice crystals formed thereby are sublimed in the vacuum provided by the freeze dryer. Eventually, the dispersion is converted to a highly porous, spongy, solid mass which can be cut to almost any desired shape, i.e. elbow, bifurcated tubes, tapered cylinder, by use of an appropriate tool. By use of such a tool, the porous mass is fashioned to a cylinder which includes the inner layer and the mandrel.
If the outer layer of the conduit is made from collagen-aminopolysaccharides, then after the freeze dried slab is cut to the desired shape and wall thickness, the mandrel with the freeze dried conduit is subjected to temperature and vacuum conditions which lightly crosslink the multilayered structure, thereby preventing collapse of pores following immersion in aqueous media during subsequent processing or applications. This treatment also serves as a first sterilization step. Following such treatment, the conduit is further crosslinked, e.g., by immersing it in an aqueous glutaraldehyde bath. This process also serves as a second sterilization step. The conduit is then rinsed exhaustively in physiological saline to remove traces of unreacted glutaraldehyde.
The preferred collagen-aminopolysaccharide outer layer of the prothesis is biodegradable at a rate which can be controlled by adjusting the amount of aminopolysaccharide bonded to collagen and the density of crosslinks. The M C for this layer is between the range of 2,000 to 60,000 with 10,000-20,000 being the preferred range. Deviations from this range give nonoptimal biodegradation rates. The required mean pore diameter is 50 microns or greater.
Optional treatments of the formed multilayered conduit include (a) seedling of the inner or outer layers by inoculation with a suspension of endothelial cells, smooth muscle cells, or fibroblasts using a hypodermic syringe or other convenient seeding procedure; and (b) encasing the conduit in a tube fabricated from a woven or knitted fabric, e.g., a polyester velour or mesh. By seeding at certain loci, cell growth occurs rapidly in places where it would be delayed if allowed to occur naturally, thereby drastically reducing the amount of time necessary to regenerate the vascular tissue. Sheathing the conduit with fabric serves to provide a mechanical reinforcement for the conduit.
The mandrel, which the multilayered conduit is mounted on, is removed preferably following the above optional processing steps and prior to storage of the sterile conduit in a container. Just prior to use, the conduit is removed from its sterile environment and used surgically as a vascular bypass, as an interposed graft or as a patch graft for the blood vessel wall.
To be suitable for vascular prostheses, vessels 10 must have certain minimum mechanical properties. These are mechanical properties which would allow the suturing of candidate vessels sections of natural vessel, a process known as anastomosis. During suturing, such vascular (blood vessel) grafts must not tear as a result of the tensile forces applied to them by the suture nor should they tear when the suture is knotted. Suturability of vascular grafts, i.e., the ability of grafts to resist tearing while being sutured, is related to the intrinsic mechanical strength of the material, the thickness of the graft, the tension applied to the suture, and the rate at which the knot is pulled closed. Experimentation performed indicates that the minimum mechanical requirements for suturing a graft of at least 0.01 inches in thickness are: (1) an ultimate tensile strength at least 50 psi; and (2) an elongation at break of at least 10%.
The best materials for vascular prostheses should duplicate as closely as possible the mechanical behavior of natural vessels. The most stringent physiological loading conditions occur in the elastic arteries, such as the aorta, where fatigue can occur as a result of blood pressure fluctuations associated with the systole-diastole cycle. The static mechanical properties of the thoracic aorta can be used as a mechanical model. The stress-strain curve of the thoracic aorta in the longitudinal direction of persons 20-29 years of age has been determined by Yamada. See Yamada, H., "Strength of Biological Materials", ed. F. G. Evans, Chapter 4, Williams & Wilkins (1970). From this plot, the mechanical properties were calculated and found to be: (1) an ultimate tensile strength of 360 psi; (2) elongation at break of 85%; (3) tangent modulus at 1% elongation of 50 psi; and (4) fracture work, i.e., the work to rupture (a measure of toughness), of 21,000 psi-%. These four mechanical properties serve as a quantitative standard for mechanical properties of vascular prostheses.
The process of the present invention is further illustrated by the following non-limiting examples.
EXAMPLE 1
The raw material for molding gas a bovine hide collagen/chondroitin 6-sulfate dispersion prepared as follows: Three grams of glacial acetic acid were diluted into a volume of 1.0 liter with distilled, deionized water to give a 0.05 M solution of acetic acid. The fibrous, freeze-dried bovine hide collagen preparation was ground in a Wiley Mill, using a 20-mesh screen while cooling with liquid nitrogen.
An Eberbach jacketed blender was precooled by circulating cold water (0°-4° C.) through the jacket. Two hundred milliliters (ml) of 0.05 M acetic acid were transferred to the blender and 0.55 g of milled collagen was added to the blender contents. The collagen dispersion was stirred in the blender at high speed over 1 hr.
A solution of chondroitin 6-sulfate was prepared by dissolving 0.044 g of the aminopolysaccharide in 20 ml of 0.05 M acetic acid to make a 8%-wt. solution (dry collagen basis). The solution of aminopolysaccharide was added dropwise over a period of 5 min to the collagen dispersion while the latter was being stirred at high speed in the blender. After 15 min of additional stirring the dispersion was stored in a refrigerator until ready for use.
The total amount of collagen-chondroitin 6-sulfate dispersion used was first treated in a blender and then fed into an air-pressurized Plexiglas tank. A magnetic stirrer bar served to minimize particle concentration gradients inside the vessel. Dispersion exited from the bottom of the pressure vessel and flowed into a flow development module and perforated aluminum tube split lengthwise which acted as a mold for tubes. Filter paper was carefully glued to each of the two halves of the aluminum tubes using alpha cyanoacrylate adhesive The flow development module and mold had an inside diameter of 0.25 inches and the flow development module was 17 in. lorg whereas the mold was 10.5 in. long. Additionally, the perforated aluminum tubing had a series of 0.03" pores extending linearly every 45" of circumference and positioned every 0.01".
Upon entry into the tubular mold, a fraction of the water of the dispersion was forced through the filter paper and subsequently through the perforation in the tube wall where it evaporated into the atmosphere giving the outside of the mold a "sweating" appearance.
While transport of a fraction of water and particles proceeded radially inside the tube mold, the decanted bulk of the dispersion inside the mold flowed uneventfully in the axial direction and was pumped back to the pressure vessel through a dispersion return line where it was stirred and recycled back into the mold.
At an applied pressure of 30 psig, and a flow rate of approximately 2.5 ml/min, a gel layer of about 0.004 inches thick had formed after a period of about 6 hours of operation which, when air dried after decanting the non-gelled fluid, was sufficiently concentrated to be handled without loss of shape. Tubes fabricated in this manner were removed from the tubular mold without being detached from the filter paper and were subjected to an insolubilization (crosslinking) treatment by immersion in 250 ml. of 0.5% w/w glutaraldehyde solution for 8 hours. The 10-inch tube obtained has a thickness of 0.0028, 0.0030, 0.0034, 0.0034 and 0.0034 inches at distances of 2, 4, 6, 8 and 10 inches, respectively, from the upstream end of the tube.
The tube was mounted on a cylindrical Plexiglas mandrel, 0.0030 inches diameter, and was immersed in the pan of a freeze dryer containing a volume of collagen-aminopolysacharide dispersion which was sufficient to cover the tube completely. The ends of the mandrel rested on supports mounted on the pan. ln this manner, the side of the tube closest to the bottom of the pan was prevented from contacting the latter.
The pan was placed on the shelf of a Virtis freeze dryer. The shelf had been precooled at -40° C. or lower by mechanical refrigeration. The chamber of the freeze dryer was closed tightly and a vacuum of 120 mTorr was established in the chamber. Several minutes after contact with the shelf, the dispersion solidified into a frozen slab which was marked by the characteristic pattern of ice crystals. The temperature of the shelf was increased to 0° C. Several hours later, the temperature of the shelf was slowly raised to 22° C. and the contents of the pan were removed in the form of a spongy, white solid slab. A specimen cut from the slab was examined in a scanning electron microscope revealing a mean pore diameter of about 80 m.
By use of a sharp tool, sufficient solid material was removed from the porous slab to expose the cylinder enclosed in the mass. A layer, approximately 1 mm thick, of porous material was left attached on the inner nonporous cylinder. The mandrel with the multilayered conduit was then placed in a vacuum oven where it was treated at 105° C. and 50 mTorr pressure over 24 hours. Following removal from the oven, the mandrel was placed in 250 ml of 0.5% w/w glutaraldehyde solution over 8 hours where it was additionally crosslinked and sterilized before being rinsed in sterile physiological saline over 24 hours to remove traces of unreacted glutaraldehyde. After removing the mandrel the multilayered conduit was stored either in 70/30 isopropanol water in a sterile container or was stored in the freeze-dried state inside a sterile container.
EXAMPLE 2
Example 1 was repeated except that 20%-wt. (dry collagen basis) of elastin was added to the collagen dispersion just before adding the mucopolysaccharide solution. Elastin was added to improve the mechanical behavior of the prosthesis by increasing the elongation to break. Elastin powder from bovine neck ligament (Sigma Chemical Co.) or Crolastin, Hydrolysed Elastin, MW 4,000 (Croda Ic., New York) were used.
EXAMPLE 3
Example 1 was repeated except that the mold used during cross flow filtration was much smaller in internal diameter, resulting in tubes with internal diameter of 2.6 mm and thickness 0.1 mm. The pressure level used to fabricate this tube was 100 psig, rather than 30 psig used in Example 1, and the total molding time was 2 hours or less under these conditions. The tubes formed thereby had a fracture stress of 200 psi and an elongation to break of 15%.
EXAMPLE 4
Example 4 was repeated except that a dispersion of endothelial cells from a canine vein was prepared according to the method of Ford et al. (J. W. Ford, W. E. Burkel and R. H. Kahn, Isolation of Adult Canine venous Endothelium for Tissue Culture, In vitro 17, 44, 1981). The cell dispersion was then inoculated into the inner layer of a multilayer conduit by use of a sterile hypodermic syringe. During inoculation the conduit was immersed in physiological saline maintained at 37° C.
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Process for forming a multilayer blood vessel prosthesis. Each layer is formed from bioreplaceable materials which include those produced by contacting collagen with an aminopolysaccharide and subsequently covalently crosslinking the resluting polymer, polymers of hydroxyacetic acid and the like. Cross flow filtration molding and wet extrusion molding are two processes which are particularly useful for forming the inner layer of the blood vessel prosthesis. The outer layer of the blood vessel prosthesis is preferably formed by freeze drying a dispersion of the bioreplaceable material onto the inner layer(s). The disclosed blood vessel prosthesis is a multilayer structure with each layer having a porosity and other physicochemical and mechanical characteristics selected to maximize the effectiveness of the blood vessel. The prosthesis funcitons initially as a thromboresistant conduit with mechanical properties which match those of the adjacent natural blood vessel. Eventually, the prosthesis functions as a regeneration template which is replaced by new connective tissue that forms during the healing process following attachment of the prosthesis.
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This application is a divisional of application Ser. No. 09/651,997, filed on Aug. 31, 2000, which is hereby incorporated by reference.
FIELD OF THE INVENTION
The present invention relates to a method and apparatus for shielding electromagnetic integrated circuits from external magnetic fields.
BACKGROUND OF THE INVENTION
A conventional integrated circuit (IC) package typically comprises (1) an IC chip or die including a plurality of input/output terminals; (2) a support for the chip, such as a pad, substrate or leadframe, including electrically conductive leads; (3) electrical connections such as wire bonds or conductive bumps for electrically connecting the input/output terminals of the chip with the electrically conductive leads; and (4) a material for encasing or encapsulating the chip, the support and the electrical connections while leaving portions of the leads accessible outside the casing or encapsulation. Fabrication of such a conventional IC package requires attaching the IC chip to the support, connecting the input/output terminals of the chip to the electrically conductive leads, and encapsulating the IC chip, the support and the electrical connections in, for example, a plastic package.
Recently, very high-density magnetic memories, such as magnetic random access memories (MRAMs), have been proposed to be integrated together with CMOS circuits. Magnetic random access memories employ one or more ferromagnetic films as storage elements. A typical multilayer-film MRAM includes a plurality of bit or digit lines intersected by a plurality of word lines. At each intersection, a ferromagnetic film is interposed between the corresponding bit line and word line to form a memory cell.
When in use, an MRAM cell stores information as digital bits, the logic value of which depends on the states of magnetization of the thin magnetic multilayer films forming each memory cell. As such, the MRAM cell has two stable magnetic configurations, high resistance representing, for example, a logic state 0 and low resistance representing, for example, a logic state 1. The magnetization configurations of the MRAMs depend in turn on the magnetization vectors which are oriented as a result of electromagnetic fields applied to the memory cells. The electromagnetic fields used to read and write data are generated by associated CMOS circuitry. However, stray magnetic fields, which are generated external to the MRAM, may cause errors in memory cell operation when they have sufficient magnitude.
Very high-density MRAMs are particularly sensitive to stray magnetic fields mainly because the minuscule MRAM cells require relatively low magnetic fields for read/write operations which, in turn, depend upon the switching or sensing of the magnetic vectors. These magnetic vectors are, in turn, easily affected and have the magnetic orientation changed by such external stray magnetic fields.
To diminish the negative effects of the stray magnetic fields and to avoid sensitivity of MRAM devices to stray magnetic fields, the semiconductor industry could introduce memory cells requiring higher switching electromagnetic fields than a stray field which the memory cells would typically encounter. However, the current requirements for operating such memory cells is greatly increased because higher internal fields necessitate more current. Thus, both the reliability and scalability of such high current devices decrease accordingly, and the use of MRAMs which may be affected by stray magnetic fields becomes undesirable.
Accordingly, there is a need for an improved magnetic memory structure and a method of forming it, which shields against external magnetic fields. There is also a need of a packaging device for encasing a magnetic random access memory IC chip which reduces the effects of external magnetic fields on internal memory cell structures and operations. There is further a need for minimizing the cost of a packaging which shields a magnetic random access memory IC chip from external magnetic fields.
SUMMARY OF THE INVENTION
The present invention provides a method and apparatus which provide a packaging device for magnetic memory structures, such as MRAMs, which shields such memory structures from external magnetic fields. The invention employs a magnetic shield, preferably formed of non-conductive magnetic oxides, which either partially contacts or completely surrounds an integrated circuit chip which includes such magnetic memory structures.
These and other features and advantages of the invention will be more clearly apparent from the following detailed description which is provided in connection with accompanying drawings and which illustrates exemplary embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of an integrated circuit package assembly at an intermediate stage of processing and in accordance with a first exemplary embodiment of the present invention.
FIG. 2 is a cross-sectional view of the integrated circuit package assembly of FIG. 1 at a subsequent stage of processing to that shown in FIG. 1 .
FIG. 3 is a cross-sectional view of the integrated circuit package assembly of FIG. 1 at a subsequent stage of processing to that shown in FIG. 2 .
FIG. 4 is a cross-sectional view of the integrated circuit package assembly of FIG. 1 at a subsequent stage of processing and in accordance with a second embodiment of the present invention.
FIG. 5 is a cross-sectional view of the integrated circuit package assembly of FIG. 1 at a subsequent stage of processing and in accordance with a third embodiment of the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
In the following detailed description, reference is made to various specific embodiments in which the invention may be practiced. These embodiments are described with sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be employed, and that structural and electrical changes may be made without departing from the spirit or scope of the present invention.
The present invention provides a method for fabricating packaging devices for electromagnetic integrated circuit structures, such as MRAM structures, to provide electromagnetic shields and to a shielded packaged electromagnetic integrated circuit structure. The present invention employs a magnetic shield, preferably formed of electrically non-conductive magnetic oxides, which either partially contacts or completely surrounds an integrated circuit chip which contains electromagnetic structures. In one exemplary embodiment of the invention, the magnetic shield is formed as a glob or layer of magnetic field shielding material which is affixed to one or more surfaces of an integrated circuit chip. In another exemplary embodiment, an encapsulating material of the chip packaging includes magnetic field shielding material therein.
Referring now to the drawings, where like elements are designated by like reference numerals, FIGS. 1-4 illustrate exemplary embodiments of the present invention. FIG. 1 depicts an integrated circuit (IC) package assembly 10 at an intermediate stage of processing. A semiconductor chip or die 12 includes an array of input/output terminals 14 and internal electromagnetic structures, such as MRAM cells and access circuitry.
The chip 12 is supported by a die pad 16 (FIG. 1) which can be formed, for example, of a leadframe or a dielectric substrate. Each of the input/output terminals 14 is further electrically connected with respective conductive leads 22 by wire bonds 20 , or other suitable electrical connectors.
Referring now to FIG. 2, a magnetic shield is provided for shielding the chip 12 from external magnetic field disturbances. According to a first exemplary embodiment of the present invention, a glob top 33 is formed over the semiconductor die 12 , including the input/output terminals 14 , and portions of the wire bonds 20 . The glob top 33 comprises an electrically non-conductive magnetic shielding material 30 , which can be injected, for example, from a nozzle. If desired, a mold can be used to shape the magnetic shielding material 30 . If a mold is used, the magnetic shielding material 30 is injected into a cavity of the mold, and flows along the top of the chip 12 , the input/output terminals 14 and adjacent portions of the wire bonds 20 which are within the mold cavity. Subsequent to the injection of the magnetic shielding material 30 into the mold cavity, the magnetic shielding material 30 hardens to form the glob top 33 , as illustrated in FIG. 2 . If a mold is not used, a nozzle can simply deposit a glob top 33 of material on the upper surface of chip 12 .
The magnetic shielding material 30 may be formed, for example, of an electrically non-conductive material with permeability higher than that of air or silicon. As such, the preferred choice for the magnetic shielding material 30 is a non-conductive magnetic oxide, for example, a ferrite such as MFe 2 O 4 , wherein M=Mn, Fe, Co, Ni, Cu, or Mg, among others. Manganites, chromites and cobaltites may be used also, depending on the device characteristics and specific processing requirements.
Further, the magnetic shielding material 30 may be also composed of magnetic particles, for example nickel or iron particles, which are incorporated into a non-conducting molding material, for example a glass sealing alloy or a polyimide. Since nickel is conductive, the concentration of nickel particles in the glass alloy should be low enough so that shielding material 30 does not form a continuous conductor if the shield extends to the input/output terminals 14 or the wire bonds 20 .
Next, as illustrated in FIG. 3, the structure of FIG. 2 is further encapsulated into a packaging material 35 , for example a plastic compound, which, as known in the art, may be injected into a mold cavity through a passage (not shown). As the packaging material 35 is injected, it flows around the glob top 33 , portions of the wire bonds 20 and conductive leads 22 , as well as around the die pad 16 . This way, the input/output terminals 14 of integrated circuitry including magnetic memory structures, such as MRAMs, are shielded by the glob top 33 and encapsulated in the packaging material 35 for enhanced protection from external stray magnetic fields.
Further, for even maximum protection, the packaging material 35 may also comprise a mold compound, such as a plastic compound, with conductive magnetic particles therein. For example, conductive magnetic particles of, for example, nickel, iron, and/or cobalt, may be suspended in a matrix material, such as a plastic compound, at a concentration that does not allow the particles to touch and form a continuous shorting conductor between the leads. Alternatively, the packaging material 35 may comprise a mold compound, such as a plastic compound, including non-conductive particles of, for example, non-conductive magnetic oxides and/or Mumetal alloys, which may comprise approximately 77% nickel (Ni), 4.8% copper (Cu), 1.5% chromium (Cr) and 14.9% iron (Fe).
Although FIGS. 2 and 3 show the magnetic shielding material 30 in the form of a rounded glob top 33 on only the top of chip 12 , it is also possible to apply a glob of shielding material 30 to the bottom surface instead, or to the top and bottom of chip 12 . Moreover, if the material of choice for the die pad 16 is a dielectric substrate, it is also possible to apply a flat layer 60 of shielding material 30 to the bottom of the chip 12 , as illustrated in FIG. 5 . In this case, the bottom flat layer 60 of shielding material 30 may be conductive or non-conductive as needed, depending on the characteristics of the IC device. A non-conductive magnetic shielding material may employ a non-conductive oxide, for example a ferrite such as MFe 2 O 4 , wherein M=Mn, Fe, Co, Ni, Cu, or Mg, among others, manganites, chromites and/or cobaltites. Similarly, a conductive magnetic shielding material may be composed of Mumetal alloys comprising approximately 77% nickel (Ni), 4.8% copper (Cu), 1.5% chromium (Cr) and 14.9% iron (Fe), or magnetic particles, such as nickel or iron particles, which are incorporated into a non-conducting molding material, for example a glass sealing alloy or polyimide. If, however, the material of choice for the die pad 16 is a lead frame comprising a magnetic material, such as the commonly used alloy 42 which already provides magnetic shielding, then the bottom flat layer 60 is optional.
FIG. 4 illustrates yet another exemplary embodiment of the present invention, in which a magnetic shielding material 50 is formed as the chip 12 encapsulating material which is used to form an IC packaging assembly 11 . The preferred material for the magnetic shielding material 50 is a non-conductive magnetic oxide, for example a ferrite such as MFe 2 O 4 , wherein M=Mn, Fe, Co, Ni, Cu, or Mg, among others. However, manganites, chromites and cobaltites may be used also, depending on the device characteristics and processing requirements. Further, conductive Mumetal alloys comprising approximately 77% nickel (Ni), 4.8% copper (Cu), 1.5% chromium (Cr) and 14.9% iron (Fe) may be used also, as well as conductive magnetic particles, such as nickel, iron or cobalt particles, incorporated into a molding material, for example a glass sealing alloy or a commercially available IC mold compound.
The magnetic shielding material 50 completely surrounds the semiconductor chip 12 . A protective plastic packaging 56 (FIG. 4 ), such as a commercially available IC mold compound, is next optionally provided to completely surround the magnetic shielding material 50 and to complete the fabrication of the IC package assembly 11 .
Although the exemplary embodiments described above refer to specific magnetic shielding materials it must be understood that the invention is not limited to the materials described above, and other magnetic shielding materials, such as ferromagnetics like nickel-iron (Permalloy), nickel or iron may be used also, as long as they are capable of shielding electromagnetic structures within chip 12 from external magnetic fields.
Further, although the exemplary embodiments described above refer to specific locations where the shielding material is applied to a die, it is also possible to apply the shielding material in other locations. For example, as described above, two globs 33 or layers of material could be employed for shielding the magnetic memories structures, one on each side of chip 12 , or multiple globs or layers of the same or different shielding material which overlap each other may be used on one or both sides of chip 12 . In addition, the specific shape of the shielding material is not limited to that shown in FIGS. 2-4 and other shapes, configurations, or geometries may be employed.
The present invention is thus not limited to the details of the illustrated embodiments mid the above description and drawings are only to be considered illustrative of exemplary embodiments which achieve the features and advantages of the present invention. Modifications and substitutions to specific process conditions and structures can be made without departing from the spirit and scope of the present invention. Accordingly, the invention is not to be considered as being limited by the foregoing description and drawings, but is only limited by the scope of the appended claims.
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Disclosed are a method and apparatus which provide a magnetic shield for integrated circuits containing electromagnetic circuit elements. The shield is formed of a magnetically permeable material, which may be a non-conductive magnetic oxide, and either partially contacts or completely surrounds the integrated circuit.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims a previous provisional patent application, No. 60/496,851 with a filing date of Aug. 21, 2003 and entitled “Vortex strake device and method for reducing the aerodynamic drag of ground vehicles”.
ORIGIN OF THE INVENTION
[[0002]] The invention described herein was made by employees of the United States Government, and may be manufactured and used by or for the Government without payment of any royalties thereon or therefore.
REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISK APPENDIX
[0003] Not applicable.
BACKGROUND
[0004] 1. Field of Invention
[0005] The invention relates to the reduction of aerodynamic drag for moving ground vehicles; specifically to an improved method and device for the reduction of aerodynamic drag and for improved performance of ground vehicles by increasing the pressure on the base area of a vehicle or vehicle component by controlling the flow in wake of the vehicle or vehicle component.
[0006] 2. Description of Prior Art
[0007] In the prior art there have been attempts to reduce the aerodynamic drag associated with the bluff base of the trailer of a tractor-trailer truck system. The wake flow emanating from the bluff base trailer is characterized as unsteady and dynamic. The unsteady nature of the wake flow is a result of asymmetric and oscillatory vortex shedding of the side surface and top surface flow at the trailing edge of the top and side surfaces of the vehicle. The boundary-layer flow passing along the top and side surfaces of the vehicle is at a low energy state and is unable to expand around the corner defined by the intersection of the side or top surfaces with the base surface. The boundary-layer flow separates at the trailing edge of the top and side surfaces and forms rotational-flow structures that comprise the bluff-base wake flow. The low energy flow separating at the trailing edges of the side surfaces and top surface of the trailer is unable to energize and stabilize the low energy bluff-base wake flow. The resulting bluff-base wake-flow structure emanating from the base area of the vehicle is comprised of the vortex structures that are shed from trailing edges of the side surfaces and top surface of the vehicle. Contributing to the low-energy bluff-base wake is the low-energy turbulent flow that exits from the vehicle undercarriage at the base of the vehicle. The unsteady wake flow imparts a low pressure onto the aft facing surface of the trailer base that results in significant aerodynamic drag. Prior art has addressed these flow phenomena by adding to the bluff base; a pre-defined aerodynamic surface referred to as a boat-tail fairings, surfaces and plates that create a cavity, and surfaces and plates that trap the vortices shed from the trailing edges. Prior art also show the forcing the side surface and top surface flow into the base region through the use of turning vanes or jets of air.
[0008] Prior art has used the aerodynamic boat-tail fairings applied to the trailer base in order to eliminate flow separation and associated drag, see U.S. Pat. Nos. 4,458,936, 4,601,508, 4,006,932, 4,451,074, 6,092,861, 4,741,569, 4,257,641, 4,508,380, 4,978,162 and 2,737,411. These representative aerodynamic boat-tail fairing devices, while successful in eliminating flow separation, are complex devices that are typically comprised of moving parts that require maintenance and add weight to the vehicle. These devices take a variety of form and may be active, passive, rigid, flexible and/or inflatable. These attributes have a negative impact on operational performance and interfere with normal operations of the vehicle.
[0009] Other concepts as documented in U.S. Pat. Nos. 5,348,366, 4,682,808 and 421,478 consist of plates or surfaces that are attached to the base of a trailer or extend from support mechanisms that are attached to the base of a trailer. These devices operate by trapping the separated flow in a preferred position in order to create an effective aerodynamic boat-tail shape. These representative trailer base devices, while successful in reducing the drag due to base flow are complex devices that are typically comprised of moving parts that require maintenance and add weight to the vehicle. All of these devices add significant weight to the vehicle. These attributes have a negative impact on operational performance and interfere with normal operations of the vehicle.
[0010] U.S. Pat. Nos. 3,010,754, 5,280,990, 2,569,983 and 3,999,797 apply a flow turning vane to the outer perimeter of the trailer base on the sides and top to direct the flow passing over the sides and top of the trailer into the wake in order to minimize the drag penalty of the trailer base flow. These devices provide a drag reduction benefit but they require maintenance and interfere with normal operations of the trailers fitted with swinging doors. These devices also add weight to the vehicle that would have a negative impact on operational performance of the vehicle.
[0011] Several concepts employ pneumatic concepts to reduce the aerodynamic drag of tractor-trailer truck systems. U.S. Pat. No. 5,908,217 adds a plurality of nozzles to the outer perimeter of the trailer base to control the flow turning from the sides and top of trailer and into the base region. U.S. Pat. No. 6,286,892 adds a porous surface to the trailer base and to the sides and top regions of the trailer abutting the trailer base. These porous surfaces cover a minimum depth plenum that is shared by the sides, top and base regions of the trailer. These two patents provide a drag reduction benefit but as with the other devices discussed previously these devices are complex devices, comprised of moving parts, interfere with normal operations of the truck and add weight to the vehicle. These characteristics of the devices result in a negative impact on the vehicle operational performance.
SUMMARY OF THE INVENTION
[0012] An object of the invention is to use a limited number of large vortex structures generated on the side and top exterior surfaces of a trailer to energize the flow exiting the trailing edge of the side and top exterior surfaces of the trailer and thereby increasing the ability of the flow on the trailer side and trailer top exterior surfaces to expand into the base region and provide drag reduction, increased fuel economy and improved operational performance. Additionally the vortex structures generated by the subject invention have a preferred angular velocity direction that enhances the mixing of the trailer undercarriage flow with the bluff-base wake flow. Aerodynamic drag reduction is created by increasing the pressure loading on the bluff-base aft-facing surface of the vehicle or vehicle component such as the trailer of a tractor-trailer truck. The invention relates to flow in the base region behind a bluff-base vehicle or vehicle component. The flow in the base region behind a bluff-base vehicle or vehicle component is a function of vehicle geometry, vehicle speed and the free stream flow direction.
[0013] The device provides improved performance for both the no crosswind condition, in which the air is still, as well as the condition when crosswind flow is present. For all moving vehicles that operate on the ground a crosswind flow is always present due to a combination of atmospheric and environmental factors and the interaction of the naturally occurring wind with stationary geological and manmade structures adjacent to the vehicle path as well as interfering flows from adjacent moving vehicles. The device is designed to reduce aerodynamic drag for the all cross wind conditions for single and multiple-component bluff-base vehicles. The subject device uses vortex flows to energize the flow on passing along the exterior top and sides surfaces of a bluff-base ground vehicle to increase the energy of the wake flow and the mixing of the wake flow with the undercarriage flow. The subject device provides reduced aerodynamic drag for all of bluff-base ground vehicles.
[0014] The present invention is a simple device comprised of a minimum number of thin, slender and rigid surfaces that attached to the side and top exterior surfaces of a ground vehicle or vehicle component. The spacing and orientation of the surfaces, comprising the device, are dependent upon the vehicle geometry and vehicle operating conditions.
[0015] The present invention pioneers a novel device that is comprised of a plurality of adjacent surfaces that are attached to the top and side exterior surfaces of a bluff-base vehicle or vehicle component. The plurality of adjacent surfaces are located forward of the base area on the vehicle. The plurality of adjacent surfaces and are distributed circumferentially over the side and top surfaces of the subject vehicle or vehicle component. To maximize the ability of each of the plurality of adjacent surfaces to generate a vortex structure the surfaces are aligned in planes or surfaces that are perpendicular to the surface of the vehicle. Each of the plurality of adjacent surfaces extends from the exterior top and side surfaces of the bluff-base vehicle. The plurality of adjacent surfaces is applied symmetrically to vehicle, about a vertical plane passing through the centerline of the vehicle. Each of the plurality of adjacent surfaces is orientated in a plane or surface that is at an angle to the local flow direction on the vehicle surface in the immediate vicinity of the present invention. The orientation and shape of the plurality of adjacent surfaces are a function of the vehicle or vehicle component geometry.
[0016] For ground vehicles such as tractor-trailer trucks, which have a cross-section shape that is predominately rectangular or square, the plurality of adjacent surfaces will be planar. The flow passing over this class of vehicle is parallel to the vehicle centerline and moving aft along the vehicle surface. The number, shape, width and orientation of the plurality of adjacent surfaces that comprise the invention are determined by; the vehicle geometry and vehicle average operating speed. The preferred embodiment of the invention is to have each of the surfaces, comprising the invention, located on the sides of the vehicle will be orientated with the leading edge positioned above the trailing edge. The surfaces located on the side of the vehicle will be evenly distributed from the lowest edge of the side surface to the highest edge of the side surface. The trailing edge of the surface located nearest the lowest edge of the side surface will be approximately coincident with the lowest edge of the side surface. The vertical position of adjacent surfaces, increasing vertical position, on the side of the vehicle will be such that the trailing edge of the adjacent surfaces is located at a vertical position that is equal to or less than the vertical position of the leading edge of the previous surface. Additional surfaces are positioned on the side of the vehicle in a similar manner with each additional surface being located at an ever-increasing vertical position. The final surface is located on the side of the vehicle with the leading edge at a vertical position coincident with the highest edge of the side of the vehicle. The preferred embodiment of the invention is to have each of the surfaces, comprising the invention, that are located on the top of the vehicle will be orientated with the leading edge positioned inboard of the trailing edge. The surfaces distributed over the top of the vehicle will be evenly and symmetrically distributed about the vehicle centerline from the outer edge of the top surface to the vehicle centerline. The trailing edge of the surface located nearest the outer edge of the top surface will be coincident with the outer edge. The position of the adjacent surface on the top of the vehicle will be such that the trailing edge is located at a lateral position that is equal to or greater than the lateral position of the leading edge of the previous surface. Additional surfaces are positioned on the top of the vehicle in a similar manner with each additional surface located at an ever-increasing inboard position. The final surface that is located on the top of the vehicle will have the leading edge at a lateral position coincident with the vehicle centerline. This arrangement of the surfaces comprising the invention ensures that the surfaces are aligned at an angle to the surface flow for this class of ground vehicle.
[0017] The reduction of aerodynamic drag, improved operational performance and improved stability of multiple component vehicles is obtained by increasing the pressure loading on the bluff base of the vehicle or vehicle component. The pressure loading on the bluff base is increased by vortex structures that are generated on the exterior surfaces of the top and sides of a vehicle. The vortex structures flow into the bluff-base region of the vehicle and energize the wake flow emanating from the bluff base. The vortex structures have a preferred rotation direction that increases the mixing of the undercarriage flow with the bluff-base wake flow. The plurality of adjacent surfaces comprising the invention, extend perpendicularly from the exterior sides and top surfaces of the vehicle. More specifically, this invention relates to a device and method for reducing aerodynamic drag utilizing a plurality of adjacent surfaces that are specifically shaped, sized, and orientated to generate vortex structures that energizes the bluff-base wake and improves mixing of the undercarriage flow with the bluff-base wake. The vortex structures energize and stabilize the wake resulting in reduced unsteady flow separation, increased pressures acting on the bluff base area and reduced vehicle aerodynamic drag. The number of surfaces, the spacing between adjacent surfaces, the length of the surfaces, the width of the surfaces and the incidence of the surfaces to the flow are the primary design variables that are used to determine vortex strength and the drag reduction capability of the device. To ensure that a vortex is formed by the interaction of the side and top surface flow with the side edge of each surface, the thickness of each surface is minimized and the leading and side edges of each surface are made aerodynamically sharp.
[0018] The invention may be used to reduce the drag of all existing and future ground vehicles (i.e., cars with trailers, tractor-trailer trucks, trains, etc.).
OBJECTS AND ADVANTAGES
[0019] Several objects and advantages of the present invention are:
(a) to provide a novel process to reduce the aerodynamic drag of vehicles; (b) to provide a means to use vortex structures to reduce aerodynamic drag; (c) to provide a means to reduce the aerodynamic drag and improve the operational efficiency of vehicles; (d) to provide a means to reduce the aerodynamic drag and improve the fuel efficiency of vehicles; (e) to provide a means to conserve energy and improve the operational efficiency of vehicles; (f) to provide a means to reduce the aerodynamic drag without a significant geometric modification to existing vehicles; (g) to provide an aerodynamic drag reduction device that uses a plurality of adjacent surfaces; (h) to allow the surface contour of each of the plurality of adjacent surfaces to be variable to meet the specific needs of the application; (i) to allow the spacing, location, and orientation of each of the plurality of adjacent surfaces to be variable to meet the specific needs of the application; (j) to create a number of high pressure and low aerodynamic drag forces on the bluff base of a vehicle that are used to reduce the aerodynamic drag of the subject vehicle; (k) to allow the device to be fabricated as a number of independent surfaces that may be applied to an existing vehicle; (l) to allow the device to be fabricated as a single independent unit that may be applied to an existing vehicle; (m) to allow the device to be fabricated as an integral part of a vehicle; (n) to allow for optimal positioning of each of the plurality of adjacent surfaces on the vehicle side surface; (o) to allow for optimal positioning of each of the plurality of adjacent surfaces on the vehicle top surface; (p) to have minimum weight and require minimum volume within the vehicle; (q) to have minimum maintenance requirements;
[0037] Further objects and advantages are to provide a device that can be easily and conveniently used to minimize aerodynamic drag on any ground vehicle for the purposes of improving the operational performance of the vehicle. Still further objects and advantages will become apparent from a consideration of the ensuing description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] FIG. 1 is a rear perspective view of the aft most portion of a trailer of a tractor-trailer truck system with the subject invention installed on the two side surfaces and top surface of the trailer.
[0039] FIG. 2 a to 2 b are cross section views, in planes horizontal to the ground ( FIG. 2 a ) and perpendicular to the ground ( FIG. 2 b ), of the wake flow conditions for a tractor-trailer system without the subject invention installed.
[0040] FIG. 2 c to 2 d are cross section views, in planes horizontal to the ground ( FIG. 2 c ) and perpendicular to the ground ( FIG. 2 d ), of the wake flow conditions for a tractor-trailer system with the subject invention installed
[0041] FIG. 3 a to 3 d are side and top views of various ground vehicles with and without the subject invention installed.
[0042] FIG. 4 a to 4 c are a perspective view and two cross section views of a fabrication and attachment technique for the subject invention applied to a vehicle.
[0043] FIG. 4 d to 4 f are a perspective view and two cross section views of a fabrication and attachment technique for the subject invention applied to a vehicle.
[0044] FIG. 5 a to 5 c are a perspective view and two cross section views of a fabrication and attachment technique for the subject invention applied to a vehicle.
[0045] FIG. 5 d to 5 f are a perspective view and two cross section views of a fabrication and attachment technique for the subject invention applied to a vehicle.
[0046] FIG. 6 a to 6 c are a perspective view and two cross section views of the subject invention fabricated as an integral part of a vehicle.
[0047] FIG. 6 d to 6 f are a perspective view and two cross section views of the subject invention fabricated as an integral part of a vehicle.
[0048] FIG. 7 a to 7 d are side views of alternate embodiments of the subject invention installed on a tractor-trailer truck.
[0049] FIG. 8 a to 8 d are side views of alternate embodiments of the subject invention installed on various ground vehicles.
[0050] FIG. 9 is a side rear perspective view of the aft portion of a trailer showing an alternate embodiment of the subject invention.
DETAILED DESCRIPTION OF THE INVENTION
[0051] The following descriptions are of exemplary embodiments of the invention only, and are not intended to limit the scope, applicability or configuration of the invention in any way. Rather the following description is intended to provide a convenient illustration for implementing various embodiments of the invention. As will become apparent, various changes may be made in the function and arrangement of the elements described herein without departing from the spirit and scope of the invention. For example, though not specifically described, many shapes, widths, leading edge shapes, spacing and orientation of the forward extended plurality of surfaces, candidate vehicles that can benefit from the device, fabrication means and material, attachments means and material should be understood to fall within the scope of the present invention.
[0052] Referring now in detail to the drawings, like numerals herein designate like numbered parts in the figures.
[0053] FIG. 1 is a rear perspective view of the aft portion of a typical trailer 30 of a tractor-trailer truck with the subject invention 40 installed on the exterior side surfaces 32 and 33 and exterior top surface 34 of a trailer 30 . The number, shape, size, and orientation of the plurality of outward extended adjacent surfaces comprising the subject invention 40 are a function of the geometry of the trailer side surfaces 32 and 33 , geometry of the trailer top surface 34 and the geometry of the trailer base surface 36 . The subject invention 40 is comprised of a plurality of outward extended surfaces that are evenly distributed circumferentially about the aft portion of the vehicle. Each surface is inclined at an angle δ to the direction of the local flow 100 passing along the side surfaces 32 and 33 and the top surface 34 of the trailer 30 .
[0054] The plurality of outward extended adjacent surfaces 40 that are attached to the side surfaces 32 and 33 of the vehicle are positioned forward of the base surface 36 a distance Xa. The distance Xa is determined by operational and maintenance requirements of the vehicle. The length La of the plurality of outward extended adjacent surfaces 40 attached to the side surfaces 32 and 33 of the trailer 30 is a function of the geometry of the side surface 32 and 33 , the incidence angle δ and operational and maintenance requirements of the vehicle.
[0055] The plurality of outward extended adjacent surfaces 40 attached to the top surface 34 of the trailer 30 are positioned forward of the base surface 36 a distance Xb. The distance Xb is determined by operational and maintenance requirements. The length Lb of the plurality of outward extended adjacent surfaces comprising the invention 40 attached to the top surface 34 of the trailer 30 is a function of the geometry of the top surface 34 , the incidence angle δ and operational and maintenance requirements of the vehicle.
[0056] The subject invention 40 provides aerodynamic drag reduction for all free stream flow 100 conditions including crosswind conditions. The subject invention 40 takes advantage of all flow 100 conditions to provide increased aerodynamic drag reduction. Aerodynamic drag reduction occurs when flow 100 encounters the leading edge and outward facing side edge of each of the plurality of outward extended surfaces comprising the subject invention 40 . The flow 100 impinging on the leading edge and outward facing side edge of each surface separates and forms and a vortex. The vortex shed from each surface comprising the invention 40 flows downstream and exits the trailing edge of both exterior side surfaces 32 and 33 and the trailing edge of the exterior top surface 34 . The vortices generated by the subject invention 40 then pass into the vehicle base area and energize the bluff-base wake flow. The vortices generate a stable bluff-base wake flow and a high pressure that acts on the exterior base surface 36 of the trailer 30 . The strength of the vortices formed by the device 40 and thus the aerodynamic drag reduction will increase with increasing velocity of the flow 100 . The vortex structures generated by the invention 40 have a preferred rotation in order to increase the mixing of the undercarriage flow with the bluff-base wake flow. The subject invention is comprised of a plurality of outward extended adjacent surfaces 40 that are evenly distributed circumferentially about the vehicle.
[0057] FIG. 2 a through FIG. 2 d show flow patterns in the wake of a bluff-base tractor-trailer truck with and without the present invention 40 installed. In FIG. 2 a through FIG. 2 d the airflow about the vehicle and in the base region is represented by arrow tipped lines and swirl structures 100 , 110 , 120 , 130 and 140 . The conical shaped structures with arrow tipped lines represent vortices 130 generated by the subject invention 40 . The shaded swirl structures represent rotational wake flow 110 . The small swirl structures represent turbulent flow structures 120 in the base area and from the vehicle undercarriage.
[0058] FIG. 2 a show a top view of the aft portion of a trailer 30 and a cross section view, in a plane horizontal to the ground, of the bluff-base wake flow, without the subject invention installed. For this condition, a surface flow 100 develops on the trailer that separates at the trailing edge of the side surfaces 32 and 33 , and forms rotational-flow structures 110 that comprise the bluff-base wake flow. The rotational-flow structures 110 are shed asymmetrically from the opposing side surfaces 32 and 33 . These rotational-flow structures 110 continue to move downstream in a random pattern. The asymmetric shedding of the rotational-flow structures 110 produce low pressures that act on the base surface 36 of the trailer. These low pressures result in a high aerodynamic drag force. The low energy flow 100 separating at the trailing edges of the side surfaces 32 and 33 of the trailer 30 is unable to energize and stabilize the low energy bluff-base wake flow. The resulting bluff-base wake-flow structure emanating from the base area of the vehicle is comprised of the vortex structures 110 that are shed from trailing edges of the side surfaces 32 and 33 of the trailer 30 . Contributing to the low-energy bluff-base wake is the low-energy turbulent flow 120 that exits from the vehicle undercarriage at the base of the vehicle.
[0059] FIG. 2 b show a side view of the aft portion of a trailer 30 and a centerline cross-section view of the bluff-base wake flow, without the subject invention installed. For this condition, a surface flow 100 develops on the trailer that separates at the trailing edge of the top surface 34 and forms rotational-flow structures 110 that comprise the bluff-base wake flow. The rotational-flow structures 110 that are shed from the trailing edge of the top surface 34 are asymmetrically located in the wake. These rotational-flow structures 110 continue to move downstream in a random pattern. The unsteady shedding of the rotational-flow structures 110 produce low pressures that act on the base surface 36 of the trailer. These low pressures result in a high aerodynamic drag force. The low energy flow 100 separating at the trailing edges of the top surface 34 of the trailer 30 is unable to energize and stabilize the low energy bluff-base wake flow. Contributing to the low-energy bluff-base wake is the low-energy turbulent flow 120 that exits from the vehicle undercarriage at the trailing edge of the vehicle. The resulting bluff-base wake-flow structure emanating from the base area of the vehicle is comprised of the vortex structures 110 that are shed from trailing edges of the side surfaces 32 and 33 and the top surface 34 of the vehicle. The low-energy turbulent flow 120 that exists from the vehicle undercarriage also enters into the bluff-base wake flow. The unsteady wake flow imparts a low pressure onto the aft facing surface 36 of the trailer base that results in significant aerodynamic drag.
[0060] FIG. 2 c and FIG. 2 d show a top view and a side view of the aft portion of a trailer 30 and cross section views in a plane horizontal to the ground and along the vehicle centerline of the bluff-base wake flow, with the subject invention 40 installed. For this condition, a surface flow 100 develops on the trailer 30 exterior top surface 34 and exterior side surfaces 32 and 33 that impinge on the leading edge and outward facing side edge of each outward-extended surface comprising the subject invention 40 . The flow 100 impinging on the plurality of outward-extended adjacent surfaces separates and forms vortices 130 . The plurality of outward-extended adjacent surfaces, comprising the subject invention 40 , is symmetrically positioned on the trailer 30 top exterior surface 34 and side exterior surfaces 32 and 33 about the vehicle centerline. Each surface of the subject invention 40 is inclined at an angle δ to the direction of the local flow 100 . Each surface 40 of the subject invention is designed to generate a coherent vortex structure 130 . The invention 40 generates a plurality of vortices 130 that are symmetrically orientated about the centerline of the trailer 30 . The vortices 130 move downstream in a symmetric pattern and exit the top surface 34 and side surfaces 32 and 33 at the trailing edge of the vehicle 30 and enter into the base region of the vehicle 30 . The vortices 130 energize the bluff-base wake flow. The vortices 130 generate a stable bluff-base wake flow and a high pressure that acts on the base surface 36 of the trailer 30 . The strength of the vortices 130 formed by the device 40 and thus the aerodynamic drag reduction benefit will increase with increasing velocity of the flow 100 . The vortex structure generated by the invention 40 has a preferred rotation in order to increase the mixing of the undercarriage flow with the bluff-base wake flow.
[0061] FIG. 3 a through FIG. 3 d are side and top views of example ground vehicles with and without the subject invention installed. FIG. 3 a shows a typical tractor-trailer truck system 1 , comprised of a powered tractor 10 that pulls a trailer 30 . The tractor 10 is comprised of a cab 11 and an aerodynamic fairing system 20 that may be an integral part of the tractor 10 . FIG. 3 b shows the same tractor-trailer truck system 1 as that of FIG. 3 a with the subject invention 40 installed on the side surfaces 32 and 33 and the top surface 34 of the trailer 30 . The plurality of outward extend adjacent surfaces that comprise the invention 40 are symmetrically distributed in a circumferential row located at the rear of the trailer 30 . FIG. 3 c and FIG. 3 d show an automobile 50 pulling a trailer 60 with and without the subject invention 40 installed on both the automobile exterior side surfaces 52 , 53 and the exterior top surface 54 and the trailer exterior side surfaces 62 , 63 and the exterior top surface 64 . The plurality of outward extend adjacent surfaces that comprise the invention 40 are symmetrically distributed in a circumferential row located at the rear of the automobile 50 and the trailer 60 . The various vehicles depicted in FIG. 3 shows a powered vehicle towing/pulling an un-powered towed vehicle. Additionally, other multiple component vehicles may be considered than those depicted.
[0062] FIG. 4 a through FIG. 4 f are perspective views and cross section views of the subject invention 40 fabricated as a single independent unit that may be applied or attached to an existing vehicle or vehicle component. FIG. 4 a through FIG. 4 c show the subject invention 40 fabricated as a single independent unit for attachment to the exterior surface of a vehicle. FIG. 4 a show the invention 40 fabricated as a single independent unit consisting of a plurality of outward extended adjacent surfaces 41 , a base plate 42 and means 43 to attach the outward extended adjacent surfaces 41 to the base plate 42 . Each of the plurality of outward extended adjacent surfaces 41 have a length La and are orientated on the base plate 42 at an angle δ. Each of the plurality of outward extended adjacent surfaces 41 have a leading edge 46 and an outward facing side edge 47 . FIG. 4 b show a cross section cut of the invention 40 , fabricated as a single independent unit, attached to the exterior surface 202 of a vehicle 200 . FIG. 4 c show a cross section cut of one outward extended adjacent surfaces 41 of the invention 40 . The sketch show the surface 41 extends perpendicularly from the surface of the vehicle a distance Ha. The angle δ and dimensions La and Ha are determined by the geometry of the vehicle 200 and direction of the air flow 100 . Example material for the outward extended adjacent surfaces 41 and the base plate 42 may be any light-weight and structurally sound wood, metal, plastic, composite or other suitable material. The material for the outward extended adjacent surfaces 41 and the base plate 42 may differ or may be of the same material and fabricated as a single component. The attachment means 43 may consist of bonding, welding or other appropriate structural attachments. The subject invention 40 is attached to the exterior surface 202 of a vehicle 200 by a means 45 . The attachments means 45 may consist of bonding, mechanical fasteners or other appropriate means.
[0063] FIG. 4 d through FIG. 4 f show the subject invention 40 fabricated as a single independent unit for attachment to the exterior surface 204 of a vehicle 200 . FIG. 4 d show the invention 40 fabricated as a single independent unit consisting of a plurality of outward extended adjacent surfaces 41 , a base plate 42 and means 43 to attach the outward extended adjacent surfaces 41 to the base plate 42 . The plurality of outward extended adjacent surfaces 41 is orientated in a symmetric pattern about the centerline A of the vehicle 200 . Each of the plurality of outward extended adjacent surfaces 41 have a length Lb and are orientated on the base plate 42 at an angle δ. Each of the plurality of outward extended adjacent surfaces 41 have a leading edge 46 and an outward facing side edge 47 . FIG. 4 e show a cross section cut of the invention 40 , fabricated as a single independent unit, attached to the exterior surface 204 of a vehicle 200 . FIG. 4 f show a cross section cut of one outward extended adjacent surfaces 41 of the invention 40 . The sketch show the surface 41 extends perpendicularly from the surface of the vehicle a distance Hb. The angle δ and dimensions Lb and Hb are determined by the geometry of the vehicle 200 and direction of the air flow 100 . Example material for the outward extended adjacent surfaces 41 and the base plate 42 may be any light-weight and structurally sound wood, metal, plastic, composite or other suitable material. The material for the outward extended adjacent surfaces 41 and the base plate 42 may differ or may be of the same material and fabricated as a single component. The attachment means 43 may consist of bonding, welding or other appropriate structural attachments. The subject invention 40 is attached to the exterior surface 204 of a vehicle 200 by a means 45 . The attachments means 45 may consist of bonding, mechanical fasteners or other appropriate means.
[0064] FIG. 5 a through FIG. 5 f are perspective views and cross section views of the subject invention 40 fabricated as a plurality of independent structures that may be applied or attached to an existing vehicle or vehicle component. FIG. 5 a through FIG. 5 c show the subject invention 40 fabricated as a plurality of independent structures for attachment to the exterior surface 202 of a vehicle 200 . FIG. 4 a show the invention 40 fabricated as a plurality of independent structures with each structure consisting of an outward extended adjacent surface 41 , a base plate 42 and means 43 to attach the outward extended adjacent surface 41 to the base plate 42 . Each outward extended adjacent surface 41 has a length La and a height Ha. Each of the plurality of independent structures is orientated on the side of vehicle at an angle δ. Each of the plurality of outward extended adjacent surfaces 41 have a leading edge 46 and an outward facing side edge 47 . FIG. 5 b show a cross section cut of the invention 40 , fabricated as a plurality of independent structures, attached to the exterior surface 202 of a vehicle 200 . FIG. 5 c show a cross section cut of one outward extended adjacent surfaces 41 of the invention 40 . The sketch show the surface 41 extends perpendicularly from the surface of the vehicle a distance Ha. The angle δ and dimensions La and Ha are determined by the geometry of the vehicle 200 and direction of the air flow 100 . Example material for the outward extended adjacent surfaces 41 and the base plate 42 may be any light-weight and structurally sound wood, metal, plastic, composite or other suitable material. The material for the outward extended adjacent surfaces 41 and the base plate 42 may differ or may be of the same material and fabricated as a single component. The attachment means 43 may consist of bonding, welding or other appropriate structural attachments. The plurality of independent structures comprising the subject invention 40 is attached to the exterior surface 202 of a vehicle 200 by a means 45 . The attachments means 45 may consist of bonding, mechanical fasteners or other appropriate means.
[0065] FIG. 5 d through FIG. 5 f show the subject invention 40 fabricated as a plurality of independent structures for attachment to the exterior surface 204 of a vehicle 200 . FIG. 5 d show the invention 40 fabricated as a plurality of independent structures with each independent structure consisting of an outward extended adjacent surface 41 , a base plate 42 and means 43 to attach the outward extended adjacent surface 41 to the base plate 42 . Each of the plurality of independent structures comprising the invention 40 is orientated in a symmetric pattern about the centerline A of the vehicle 200 . Each of the plurality of independent structures comprising the invention 40 has a length Lb and are orientated on the exterior surface 204 of the vehicle 200 at an angle δ. Each of the plurality of outward extended adjacent surfaces 41 have a leading edge 46 and an outward facing side edge 47 . FIG. 5 e show a cross section cut of the invention 40 , fabricated as a plurality of independent structures, attached to the exterior surface 204 of a vehicle 200 . FIG. 5 f show a cross section cut of one outward extended adjacent surface 41 of the invention 40 . The sketch show the surface 41 extends perpendicularly from the surface of the vehicle a distance Hb. The angle δ and dimensions Lb and Hb are determined by the geometry of the vehicle 200 and direction of the air flow 100 . Example material for the outward extended adjacent surfaces 41 and the base plate 42 may be any light-weight and structurally sound wood, metal, plastic, composite or other suitable material. The material for the outward extended adjacent surfaces 41 and the base plate 42 may differ or may be of the same material and fabricated as a single component. The attachment means 43 may consist of bonding, welding or other appropriate structural attachments. The subject invention 40 is attached to the exterior surface 204 of a vehicle 200 by a means 45 . The attachments means 45 may consist of bonding, mechanical fasteners or other appropriate means.
[0066] FIG. 6 a through FIG. 6 f are perspective views and cross section views of the subject invention 40 fabricated as an integral part of an existing vehicle 200 or vehicle component. FIG. 6 a through FIG. 6 c show the subject invention 40 fabricated as an integral part of the exterior surface 202 of a vehicle 200 . FIG. 6 a show the invention 40 fabricated as an integral part of an existing vehicle 200 with the subject invention consisting of a plurality of outward extended adjacent surfaces 41 fabricated as part of the surface 202 . Each outward extended adjacent surface 41 has a length La and a height Ha. Each of the plurality of independent structures is orientated on the vehicle at an angle δ. Each of the plurality of outward extended adjacent surfaces 41 have a leading edge 46 and an outward facing side edge 47 . FIG. 6 b show a cross section cut of the invention 40 , fabricated as an integral part of the surface 202 of a vehicle 200 . FIG. 6 c show a cross section cut of one outward extended adjacent surfaces 41 of the invention 40 . The sketch show the surface 41 extends perpendicularly from the surface of the vehicle a distance Ha. The angle δ and dimensions La and Ha are determined by the geometry of the vehicle 200 and direction of the air flow 100 . Example material for the outward extended adjacent surfaces 41 may be any light-weight and structurally-sound wood, metal, plastic, composite or other suitable material. The material for the outward extended adjacent surfaces 41 and the vehicle 200 may differ or may be of the same material and fabricated as a single component. The plurality of independent structures comprising the subject invention 40 is fabricated as part of the exterior surface 202 of a vehicle 200 .
[0067] FIG. 6 d through FIG. 6 f show the subject invention 40 fabricated as an integral part of the exterior surface 204 of a vehicle 200 . FIG. 6 d show the invention 40 fabricated as an integral part of the surface 204 of a vehicle 200 consisting of a plurality of outward extended adjacent surfaces 41 . Each of the plurality of outward extended adjacent surfaces 41 comprising the invention 40 is orientated in a symmetric pattern about the centerline A of the vehicle 200 . Each of the plurality of outward extended adjacent surfaces 41 comprising the invention 40 has a length Lb and is orientated on the surface 204 of the vehicle 200 at an angle δ. Each of the plurality of outward extended adjacent surfaces 41 have a leading edge 46 and an outward facing side edge 47 . FIG. 6 e show a cross section cut of the invention 40 , fabricated as a plurality of outward extended adjacent surfaces 41 , attached to the top surface 204 of a vehicle 200 . FIG. 6 f show a cross section cut of one outward extended adjacent surface 41 of the invention 40 . The sketch show the surface 41 extends perpendicularly from the surface of the vehicle a distance Hb. The angle δ and dimensions Lb and Hb are determined by the geometry of the vehicle 200 and direction of the air flow 100 . Example material for the outward extended adjacent surfaces 41 may be any light-weight and structurally sound wood, metal, plastic, composite or other suitable material. The material for the outward extended adjacent surfaces 41 and the vehicle 200 may differ or may be of the same material. The subject invention 40 is attached to the exterior surface 204 of a vehicle 200 .
[0068] FIG. 7 a to 7 d are side views of various embodiments of the subject invention 40 installed on a tractor-trailer truck 1 . FIG. 7 a is a side view of a tractor-trailer truck 1 with the subject invention 40 , comprised of a minimal number of outward projected adjacent surfaces orientated with a large incidence angle δ, installed in the furthest aft position on the trailer 30 exterior side surfaces 32 and 33 and exterior top surface 34 . FIG. 7 b is a side view of a tractor-trailer truck 1 with the subject invention 40 , comprised of a minimal number of outward projected adjacent surfaces orientated with a large incidence angle δ, installed in a forward position on the trailer 30 exterior side surfaces 32 and 33 and exterior top surface 34 . FIG. 7 c is a side view of a tractor-trailer truck 1 with the subject invention 40 , comprised of a increased number of outward projected adjacent surfaces orientated with a reduced incidence angle δ, installed in an aft position on the trailer 30 exterior side surfaces 32 and 33 and exterior top surface 34 . FIG. 7 d is a side view of a tractor-trailer truck 1 with the subject invention 40 , comprised of a increased number of outward projected adjacent surfaces with a reduced length La and Lb and a large incidence angle δ, installed in the aft position on the trailer 30 exterior side surfaces 32 and 33 and exterior top surface 34 .
[0069] FIG. 8 a to 8 d are side views of various embodiments of the subject invention 40 installed on various ground vehicles. FIG. 8 a is a side view of a surface truck 130 with the subject invention 40 , comprised of a minimal number of outward projected adjacent surfaces orientated with a large incidence angle δ, installed in the furthest aft position on the truck 130 exterior side surfaces 132 and 133 and exterior top surface 134 . FIG. 8 b is a side view of a pick-up truck 1 with the subject invention 40 , comprised of a large number of outward projected adjacent surfaces orientated with a small incidence angle δ, installed on the pick-up cab exterior side surfaces 142 and 143 and exterior top surface 144 and the pick-up bed exterior side surfaces 145 and 146 . FIG. 8 c is a side view of a van 150 with the subject invention 40 , comprised of a increased number of outward projected adjacent surfaces orientated with a reduced incidence angle δ, installed in an aft position on the van 150 exterior side surfaces 152 and 153 and exterior top surface 154 . FIG. 8 d is a side view of a bus 160 with the subject invention 40 , comprised of a increased number of outward projected adjacent surfaces with a reduced length and a large incidence angle δ, installed in the aft position on the bus 160 exterior side surfaces 162 and 163 and exterior top surface 164 .
[0070] FIG. 9 is a rear perspective view of the aft portion of a typical trailer 30 of a tractor-trailer truck showing an alternate embodiment of the subject invention 40 installed on the exterior side surfaces 32 and 33 and exterior top surface 34 of a trailer 30 . The number, shape, size, and orientation of the plurality of outward extended adjacent surfaces comprising the subject invention 40 are a function of the geometry of the trailer exterior side surfaces 32 and 33 , geometry of the trailer exterior top surface 34 and the geometry of the trailer exterior base surface 36 . The subject invention 40 is comprised of a plurality of outward extended surfaces that are evenly distributed circumferentially about the aft portion of the vehicle. Each surface is inclined at an angle δ to the direction of the flow 100 passing along the exterior side surfaces 32 and 33 and the exterior top surface 34 of the trailer 30 . The leading edge of each outward projected surface, comprising the invention 40 , located on the exterior side surfaces 32 and 33 of the trailer 30 are orientated with the leading edge of each surface at a vertical position that is below the trailing edge of each surface. The leading edge of each outward projected surface, comprising the invention 40 , located on the exterior top surface 34 of the trailer 30 are orientated with the leading edge of each surface positioned outboard of the trailing edge of each surface.
[heading-0071] Advantages
[0072] From the description provided above, a number of advantages of the vortex strakes become evident:
[0073] The invention provides a novel process to reduce the drag of a bluff-base body.
(a) The invention provides a means to use vortices generated on the top and side surfaces of a bluff-base body to reduce drag. (b) The invention provides a means to reduce the aerodynamic drag and improve the operational efficiency of bluff-base vehicles. (c) The invention provides a means to reduce the aerodynamic drag and improve the fuel efficiency of bluff-base vehicles. (d) The invention provides a means to conserve energy and improve the operational efficiency of bluff-base vehicles. (e) The invention provides a means to reduce the aerodynamic drag without a significant geometric modification to existing bluff-base vehicles. (f) The invention may be easily applied to any existing bluff-base vehicle or designed into any new bluff-base vehicle. (g) The invention allows for the efficient operation of the invention with a limited number of outward extended surfaces. (h) The invention allows for the matching of complex surface shapes by the shaping and placement of the plurality of outward extended surfaces. (i) Large reductions in drag force can be achieved by the plurality of vortices. (j) The structure of each outward extended surface may be adapted to meet specific performance or vehicle integration requirements. (k) The shape of each single outward extended surface may be planar, cylindrical, or combinations thereof to meet specific performance or vehicle integration requirements. (l) The ability to optimally position each outward extended surface on the vehicle top surface and side surfaces. (m) The ability to minimize weight and volume requirements within the vehicle. (n) The ability to minimize maintenance requirements. (o) The ability to maximize the safety of vehicle operation.
Conclusion, Ramifications, and Scope
[0090] Accordingly, the reader will see that the vortex strake device can be used to easily and conveniently reduce aerodynamic drag on any ground vehicle for the purposes of improving the operational performance of the vehicle. Furthermore, the plurality of outward extended adjacent surfaces comprising the vortex strake device has the additional advantages in that:
it provides a aerodynamic drag reduction force over the base of the vehicle; it allows the contour of the host surface to be easily matched; it allows easy application to any existing vehicle or designed into any existing vehicle; it allows the device to be fabricated as an independent unit that may be applied to an existing surface; it allows for optimal positioning of each outward extended surface on the vehicle side surfaces and top surface; it allows the design of a system with minimum weight and to require minimum volume within the vehicle; it allows minimum maintenance requirements; it allows for the maximum safety of vehicle operation;
[0099] Although the description above contains many specificities, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments of this invention. For example, the outward projected surfaces can have various non-planar shapes such as ellipsoid, complex, etc.; the thickness and width can vary along the length; the material can be any light-weight and structurally sound material such as wood, plastic, metal, composites, etc.; the substrate can be any metal, wood, plastic, composite, rubber, ceramic, etc.; the application surface can be that of a metal, wood, plastic, composite, rubber, ceramic, etc.
[0100] The invention has been described relative to specific embodiments thereof and relative to specific vehicles; it is not so limited. The invention is considered applicable to any road vehicle including automobiles, trucks, buses, trains, recreational vehicles and campers. The invention is also considered applicable to non-road vehicles such as hovercraft, watercraft, aircraft and components of these vehicles. It is to be understood that various modifications and variation of the specific embodiments described herein will be readily apparent to those skilled in the art in light of the above teachings without departing from the spirit and scope.
[0101] Thus, the scope of the invention should be determined by the appended claims and their legal equivalents, rather than by the examples given.
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An improved method and device for the reduction of aerodynamic drag and for improved performance of vehicles by increasing the pressure on the rear surface of the vehicle by generating a plurality of vortices along the top and side surfaces that flow in to the base wake region of the vehicle. An improved method and device for generating a reduction in the drag force on a moving object. The present invention is a simple device comprised of a minimum number of thin and slender small surfaces that are attached to or fabricated as part of the side and top exterior surfaces of a vehicle or vehicle component. The spacing and orientation of the small surfaces, comprising the device, are dependent upon the vehicle geometry and vehicle operating conditions. The plurality of adjacent small surfaces are located forward of the base area on the vehicle. The plurality of adjacent small surfaces and are distributed circumferentially over the side and top surfaces of the subject vehicle or vehicle component. To maximize the ability of each of the plurality of adjacent small surfaces to generate a vortex structure the small surfaces are aligned in planes that are perpendicular to the surface of the vehicle. Each of the plurality of adjacent small surfaces extends from the exterior top and side surfaces of the vehicle. The plurality of adjacent small surfaces is applied symmetrically to a vehicle, about a vertical plane passing through the centerline of the vehicle. Each of the plurality of adjacent small surfaces is orientated in a plane or surface that is at an angle to the local flow direction on the vehicle surface in the immediate vicinity of the present invention. The orientation and shape of the plurality of adjacent small surfaces are a function of the vehicle or vehicle component geometry.
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The invention relates to the filed of transmitting digital data by optical means. It is more particularly concerned with transmission of high bit rates with effective management of bandwidth.
BACKGROUND OF THE INVENTION
Such transmission uses an optical transmitter connected to an optical receiver by the fiber. The transmitter generally modulates the power of an optical carrier wave from a laser oscillator as a function of the information to be transmitted. NRZ modulation is very frequently used and entails varying the power of the carrier wave between two levels: a low level corresponding to extinction of the wave and a high level corresponding to a maximum optical power. The variations of level are triggered at times imposed by a clock rate and this defines successive time cells allocated to the binary data to be transmitted. By convention, the low and high levels respectively represent the binary values “0” and “1”.
The maximum transmission distance is generally limited by the ability of receivers to detect without error these two power levels after the modulated wave has propagated in the optical link. The usual way to increase this distance is to increase the ratio between the average optical power of the high levels and that of the low levels, this ratio defining the “extinction ratio” which is one of the characteristics of the modulation.
Various modulation schemes for optical communications systems are known in the art. Frequency or phase modulation are utilized in optical communications technology in addition to intensity or amplitude modulation.
The Non-Return-to-Zero (NRZ) signal format is transmitting data in form wherein d(t)=0 is valid for a binary “0” and d(t)=1 is valid for a transmitted binary symbol “1” during the entire duration of a bit T (see for example, R. S. Vodhanel, Electronics Letters, Vol. 24 No. 3, pp. 163-165 (1988).
As the demand for faster communications increases, there has been a natural evolution towards a better usage of channel bandwidth. Optical fiber communications offers such a large usable bandwidth that efficient channel usage has not been an issue until recently. One modulation scheme for attacking the challenge of bandwidth management is the duobinary modulation This modulation may be the next step in the evolution of spectrally more efficient formats in optical fibers. Duobinary format is a binary NRZ signal with spectral shaping due to correlation between adjacent bits. This modulation scheme has four attractive features: (1) narrower bandwidth than binary format and hence suffers less from dispersion, (2) greater spectrum efficiency than binary format and hence allows tighter packing of wavelength division multiplexed channels, (3) less stimulated Brillouin backscattering, the major limiting factor in repeaterless transmission, and (4) ease of implementation. Duobinary format is new to the optical communications community and hence there are many unresolved issues. It is a relatively complicated modulation scheme which dispersion advantages depends from modulation, phase variation.
Another approach to achieve an effective bandwidth management is the Phase Shaped Binary Transmission (PSBT) scheme as described in D. Penninckx, “Enhanced Phase Shape binary Trnasmission”, Electronic Letters, March 2000, page 478-480. This paper describes a variant of the duobinary transmission which is more tolerant towards chromatic dispersion than a pure NRZ modulation. With this modulation scheme the tolerance of signal-to noise ratio degradation is reduced.
In a wavelength division multiplex transmission scheme with a ITU grid of wavelength for example a transmission data rate of 40 Gbit/s is achieved with 16 different wavelengths and a 50 GHz spacing between the different wavelengths.
The ITU recommendations allows a wavelength comb with spacings of 100 GHz or 50 GHz. For the bandwidth per wavelength channel depends of the data rate a data rate of 10 Gbit/s can be transmitted with 50 GHz spacing. But with increasing bitrates the bandwidth per channels also increases.
One get to a special point when the spacing of 50 GHz is not broad enough to use the pure NRZ modulation method as described in the prior art at high bit rates Therefore one solution would be to increase the spacing between the wavelengths up to 100 GHz.
OBJECTS AND SUMMARY OF THE INVENTION
The aim of the invention is to propose a modulation scheme that is based on a NRZ amplitude modulation scheme but decreases the bandwidth per wavelength channels.
This new modulation scheme fits with the ITU wavelength grid for WDM transmissions over fiber in a bit range of 40 Gbit/s and more. The new NRZ modulation decreases the bandwidth of the channels. The new NRZ modulation scheme has a better tolerance to signal-to noise ratio SNR degradation.
DRAWINGS
Other aspects and advantages of the invention become apparent in the remainder of the description which refers to the figures.
FIG. 1 shows an optical transmitter
FIG. 2 shows the result of the modulation scheme.
FIG. 3 shows a comparison of spectra of 3 wavelength channels
FIG. 4 shows a time diagramm of phase and intensity.
DESCRIPTION
FIG. 1 shows an optical transmitter. The transmitter contains a laser source 6 connected with a waveguide 1 . the waveguide 1 is connected to a Mach Zehnder structure 4 .
A Mach Zehnder modulator principally comprises an interferometer structure with an input optical guide that splits into two branches that are combined to form an output guide. Electrodes apply respective electric fields to the two branches. When the input optical guide receives a carrier wave of constant power, two partial waves propagate in the two branches and then interfere at the output. The output guide then supplies a wave whose power and phase depend on the values of the electrical control voltages applied to the electrodes.
In FIG. 1 the Mach-Zehnder electro-optical modulator consists of an interferometer structure 7 , 8 and an electronic control circuit 3 . The electronic control circuit 3 is connected to electrodes E 1 and E 2 . In one of the connection lines a time delay circuit 5 is built in.
In a manner that is known, the structure of the Mach Zehnder Interferometer 4 can be formed on a lithium niobate (LiNbO 3 ) substrate. A structure with the same configuration on a substrate of III-V elements, such as indium phosphide InP, can be used instead. The structure 4 includes an entry guide 1 which splits into two branches 7 , 8 which then join again to form an output guide 2 . Respective electrodes E 1 ,E 2 on the branches 7 , 8 receive voltages V 1 , V 2 from the control circuit 3 . A third electrode on the bottom face of the structure 4 is connected to earth.
The control circuit 3 delivers the electrical input signal V and its complement V* to the electrodes E 1 and E 2 .
Additional to the known push pull modulator the transmitter contains a time delay mean 5 in the control connection between the control circuit 3 and the electrode E 2 .
This time delay mean implements a temporal shift between the pulses in the both branches of the modulator. This gives a third level in the temporal pulses as can be seen in FIG. 2 and a reduction in spectral width together with an absolute shift. The delay between the arms depends on the bitrate of the signal. Good results can be obtained with T=bitrate/2. The range in between the transmission can be optimized is bitrate/4 to 3×bitrate/4.
FIG. 2 show in the left part the spectra of a conventionally modulated NRZ signal. The three graphs show from top to bottom the frequency spectrum of the NRZ signal with the peak for the DC component in the base band, the eye diagram at the transmitter and the eye diagram after rectangular filter of a band width of 1.2/T.
On the right side the corresponding three charts show the results by using the new modulation scheme. The frequency spectrum is shifted and the spectral width is reduced. In the eye diagram a third level occurs and the results after optical filter are much better compared to the conventional NRZ modulation.
In the FIG. 3 the advantages of the NRZ modulation with delayed signals are shown more clearly. The spectra of a wavelength comb of three different wavelengths are plotted. The spectra of the NRZ modulated signals are overlapping in the region between the baseband signals. For the modified NRZ modulation a bandwidth reduction is sufficient to avoid overlapping of the bandwidth of each channel.
Also the eye diagrams after transmission are shown. One can see the improvement of the transmission in the better eye opening.
Actually also some phase variation is generated in this modulation scheme.
But it can be positively influencing the transmission quality in a propagation using standard fibers. The only problem is then to choose the adequate chirping of the phase.
The problem of phase variation can be solved using an other embodiment of the invention. In this embodiment two delay means 5 are built in both connection to the electrodes E 1 and E 2 . The control circuit 3 has an additional connection to the delay means 5 and activate the time delay of one or the other delay mean.
This solution allows an adaptation of the modulation to the transmission line The diagram of FIG. 4 shows the phase and the intensity of NRZ format with delays signals. By delaying the other arm of the Mach-Zehnder modulator reverse phase shifts are produced with the same intensity diagram.
The modified NRZ modulation can achieve a 0.8 bit/s/Hz spectral efficiency. Therefore a use of 40 Gbit/s with a channels spacing of 50 GHz is possible.
The described embodiment is one solution to achieve a modulation scheme with reduced bandwidth. The invention of the modified NRZ modulation is not limited to this example.
The optical transmitter 10 can be used in every transmission system especially in a WDM transmission system. In WDM system the modified NRZ signal from each transmitter is combined in an optical multiplexer. The modified NRZ is less sensitive to the filtering function of said multiplexers as for example phase array gratings.
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An optical modulation scheme for transmitting data over a fiber optic transmission line is proposed where the following steps are realized: creating a NRZ signal by amplitude modulation, modulating two branches of a interferometer structure by complementary electrical signals, and shifting one of the electrical signals against the other electrical signal in time. Further, an optical transmitter is proposed which can modulate the light in the new proposed modulation scheme.
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BACKGROUND OF THE INVENTION
The instant invention relates generally to toilet flush valve systems and more specifically it relates to a dual handle semi-flush retrofit kit.
Numerous toilet flush valve systems have been provided in the prior art that are adapted to regulate the volume of water discharged for flushing when evacuating toilet bowls. For example, U.S. Pat. Nos. 3,325,828 to Alexander; 4,483,024 to Troeh; 4,504,984 to Burns and 4,620,331 to Sagueio all are illustrative of such prior art. While these units may be suitable for the particular purpose to which they address, they would not be as suitable for the purpose of the present invention as hereafter described.
SUMMARY OF THE INVENTION
A primary object of the present invention is to provide a dual handle semi-flush retrofit kit that will overcome the shortcomings of the prior art devices.
Another object is to provide a dual handle semi-flush retrofit kit that includes double flush handles, such that if one handle is pressed downward the toilet is flushed fully in the conventional way, and if the other handle is pressed downward, the tank is partially emptied.
An additional object is to provide a dual handle semi-flush retrofit kit that includes a water releasable reservoir cup which can control the amount of water that is flushed into the toilet bowl so as to save many gallons of water over a long period of time.
A further object is to provide a dual handle semi-flush retrofit kit that is simple and easy to use, and can be easily installed by the do-it-yourself home owner.
A still further object is to provide a dual handle semi-flush retrofit kit that is economical in cost to manufacture.
Further objects of the invention will appear as the description proceeds.
To the accomplishment of the above and related objects, this invention may be embodied in the form illustrated in the accompanying drawings, attention being called to the fact, however, that the drawings are illustrative only and that changes may be made in the specific construction illustrated and described within the scope of the appended claims.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
The figures in the drawings are briefly described as follows:
FIG. 1 is a perspective view of a toilet with the instant invention installed thereon;
FIG. 2 is an partial elevational view of just the flush mechanism taken in the direction of line 2--2 in FIG. 1;
FIG. 3 is an enlarged top view of the reservoir cup as indicated by arrow 3 in FIG. 2;
FIG. 4 is a cross sectional view through the reservoir cup taken along line 4--4 in FIG. 3; and
FIG. 5 is an enlarged cross sectional view taken along line 5--5 of FIG. 1, with parts broken away showing the double flush handles in greater detail.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning now descriptively to the drawings, in which like reference characters denote like elements throughout the several views, the Figures illustrate a dual handle semi-flush retrofit kit 10 for use in a toilet 12 of the type having a tank 14, a flush port 16, a valve seat 18, an overflow tube 20, and a flapper flush valve 22. The kit 10 consists of double flush handles 28 and 30 adapted to be concentrically pivotally mounted at 32 to the toilet tank 14 so that each handle 28 and 30 can independently rotate counter-clockwise on the toilet tank 14.
A reservoir cup 34, for holding water therein, is carried on the lift wire 26. A first mechanism 36 is coupled between the first handle 28 and the reservoir cup 34, for causing a conventional full flush cycle F in the toilet tank 14, when the first handle 28 is manually rotated counter-clockwise on the toilet tank 14 to open and close the flapper flush valve 22 on the valve seat 18. A second mechanism 38 is coupled between the second handle 30 and the reservoir cup 34, for causing a semi-flush cycle S in the toilet tank 14, when the second handle 30 is manually rotated counter-clockwise on the toilet tank 14 to open and close the flapper flush valve 22 sooner on the valve seat 18.
The first mechanism 36 includes a first lift arm 40 coupled to the first handle 28 so that the first lift arm 40 will be lifted in a counter-clockwise direction when the first handle 28 is manually rotated counter-clockwise. A first flexible lanyard 42 is connected between an end of the first lift arm 40 and the reservoir cup 34. A structure 43 in the reservoir cup 34 is for releasing water out of the bottom 44 of the reservoir cup 34 when the first handle 28 is manually rotated counter-clockwise thereby causing the flapper flush valve 22 to close slowly for the conventional full flush cycle F in the toilet tank 14.
A deflector shield 45 is secured to the guide arm 24 between the bottom 44 of the reservoir cup 34 and the top of the flapper flush valve 22 so as to protect the flapper flush valve 22 from the pressure of the water spilling out of the tank through flush port 16. An adjustment clamp 46, having a knurled thumb screw 48 is interposed on the lift wire 26 which is split and overlapped so as to permit adjustment to the height setting of the reservoir cup 34 carried on the lift wire 26.
The second mechanism 38 includes a second lift arm 48 coupled to the second handle 30 so that the second lift arm 48 will be lifted in a counterclockwise direction when the second handle 30 is manually rotated counter-clockwise. A second flexible lanyard 50 is connected between an end of the second lift arm 48 and the reservoir cup 34. Another structure 52 in the reservoir cup 34 is for retaining water within the reservoir cup 34. When the second handle 30 is manually rotated counter-clockwise, this allows the flapper flush valve 22 to close faster for the semi-flush cycle S in the toilet tank 14. This because the weight of water 74 contained within the reservoir cup 34 lowers the total effective buoyancy of the flapper flush valve 22 so that as water drains from the toilet tank the flapper flush valve 22 is caused to seat soon in the semi-flush cycle S due to the additional force from the weight of this water 74 which is not other wise present during a full flush cycle F because it has been allowed to spill from the reservoir cup 34 at the beginning of a full flush cycle F as indicated by arrow 72.
The water releasing structure 43 includes a cross bar structure 54 having a top eyelet 56 that is secured to the open top 57 of the reservoir cup at 58, so that the first flexible lanyard 42 can be connected to the top eyelet 56. The reservoir cup 34 has a first annular inner flange 60 at the bottom thereof and a plurality of portholes 62 above the first annular flange 60. A circular plate 64 is secured at 66 to the upper portion of the lift wire 26 within the reservoir cup 34, so as to sit upon the first annular inner flange 60 to expose the portholes 62 and release the water 74 as indicated by arrow 72 when the first flexible lanyard 42 pulls the top eyelet 56, and lifts only the reservoir cup 34 causing portholes 62 to be thereby opened.
The water retainer structure 52 includes the lift wire 26 having an eye 65 formed on its upper end within the reservoir cup 34. The bottom eyelet 68 is on the cross bar 54 so that the second flexible lanyard 50 can extend through the eye 65 the lift wire 26 and be connected to the bottom eyelet 68. The reservoir cup 34 has a second annular inner flange 70 proximate the bottom 44 thereof above the porthole 62, so that the circular plate 64 can bear against the second annular inner flange 70 to seal the bottom 44 of the reservoir cup 34 and retain the water therein when the second flexible lanyard 50 pulls the bottom eyelet 68.
Naturally when the water 74 is spilled during a full flush cycle F it is replenished when the toilet tank is refilled toward the end of the fill as the water level reaches sufficient height to flow over the open top 57 of the reservoir cup 34.
The guide arm 24 provides the mechanism by which the flapper valve-reservoir cup assembly is affixed to the overflow tube 20. It is placed on the tube and lowered to the point where the flapper valve can be attached. The knurled thumb screw 25 is then turned to lock it in place.
While certain novel features of this invention have been shown and described and are pointed out in the annexed claims, it will be understood that various omissions, substitutions and changes in the forms and details of the device illustrated and in its operation can be made by those skilled in the art without departing from the spirit of the invention.
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A dual handle semi-flush retrofit kit is provided and consists of a water releasable reservoir cup the weight of which varies the effective buoyancy of the flapper flush valve, connected between the flapper flush valve and double flush handles on a toilet tank, such that if one handle is operated the toilet tank is fully flushed in the conventional way. If the other handle is operated the toilet tank is only half emptied thereby saving many gallons of water. This dual handle semi-flush retrofit kit can be easily installed by the do-it-yourself home owner.
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BACKGROUND OF THE INVENTION
The present invention relates to an automatic exchanging apparatus for exchanging cops in a shuttle-type loom. More particularly, the invention relates to an automatic cop exchanging apparatus for exchanging an old cop received in a shuttle with warp threads for a new cop.
In general, in a conventional loom employing shuttles, opening operations for repeatedly separating the wefts into upper and lower groups are repeatedly performed, while simultaneously the shuttle incorporating therein the warps is passed between the upper and lower wefts in synchronism with the opening operation. For example, as shown in FIGS. 2A and 2B, the convention shuttle 1, which has generally a boat-like shape, has a recess 1a which receives an elongated cop 2 around which the threads of the weft 4 are wound. A tong is provided in a rear portion of the recess 1a mounted so as to be rotatable through about 90° so as to be movable from a horizontal position to a vertical position. The cop 2 is received in a horizontal position within recess 1a under the condition that the tong 3 is inserted into a hole 2a formed in the bottom of the cop 2. Then, the wefts 4 are extracted to the outside through a hole 1b formed in the front portion of the shuttle 1.
With this construction, the amount of weft 4 held within the shuttle 1 decreases as the shuttle performs its reciprocating motion. When the weft has been completely consumed, it is necessary to stop the operation of the machine. Therefore, in the conventional machine, when it is observed that the remaining amount of the weft 4 is small, the operator, who, for this purpose, must stand by the machine, must manually perform the exchange of cops. That is, the weft of the old cop, which has nearly been expended, is cut and the old cop manually removed from the shuttle 1. Then, a new cop is loaded into the shuttle 1, and the new and old threads are tied together.
Generally, therefore, it is necessary that an individual operator be assigned to each loom during its operation since the cops 2 must be replaced frequently. This of course is a major factor in the total labor costs for operating the loom, Also, since looms employing high speed shuttles are inherently very noisy, the operator may fatigue easily.
Thus, it is desirable to reduce the cost of operating a loom while simultaneously improving the quality of the working environment around the loom. In the prior art, however, due to the complexities of the operations involved in handling the threads, automation of the cop-replacing operation had not be attained.
SUMMARY OF THE INVENTION
Overcoming the above-discussed drawbacks of the prior art, the invention provides an automatic cop exchanging apparatus for exchanging a cop on which weft yarn is wound in a loom in which a shuttle is passed between upper and lower warps. The automatic cop exchanging apparatus includes a hand for gripping a cop, a rotary arm plate on which the hand is mounted, drive means for rotating the rotary arm plate and for straightly moving the rotary arm plate in an axial direction of rotation, and a drive shaft for moving the rotary arm plate to an exchange position for the cop.
Further, the invention provides an automatic cop exchanging apparatus for exchanging a cop on which weft yarn is wound in a loom for producing woven material in which a shuttle is passed between upper and lower warps, the apparatus including, cop pick up means for picking up a new cop and delivering the new cop to a predetermined position, cop setting means for picking up an old cop within the shuttle, receiving the new cop delivered by the pickup means, and setting the new cop in the shuttle, thread processing means for processing the threads of the new and old cops by making the threads of the new and old cops coincide in position, tying means for tying the ends of the threads together, and reel means for diffusing positions of the knot portions of the tied treads through woven material.
In accordance with another aspect, the invention provides an adjusting device for a loom in which weaving is effected by passing a shuttle containing a cop around which a weft yarn is wound between upper and lower warp yarns, the adjusting device including a disc-shaped reel provided with circumferential channel parts for accommodating a wound thread thereon, thread holding means projecting outward of the circumferential channel parts of the reel for holding threads, and hooking means for hooking the threads held by the holding means and rotating the threads so as to twist the threads, thereby winding the twisted threads onto the circumferential channel parts of the reel.
In accordance with still another aspect, the invention provides a thread tying apparatus including a pair of gripper claw means for gripping old and new threads at two respective locations, and then performing a rotating and retracting movement to form crossing points in the threads, pressing lever means for locating the crossing points to one side, and gripping claw means for gripping a part of the threads located on the one side and tensioning the threads to tie a single-bundle knot with the old and new threads.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagonal view of a loom and automatic cop-replacing apparatus constructed in accordance with the present invention.
FIGS. 2A and 2B are sectional views of a shuttle with a cop placed therein, of which FIG. 2A shows the vertical posture of the cop at the time of its replacement while FIG. 2B shows the state of a cop accommodated inside the shuttle.
FIG. 3 is a front view of a cop-unloading apparatus;
FIG. 4 is a sectional view of the cop-unloading apparatus of FIG. 3.
FIG. 5 shows a front view showing relations in the arrangement of the various apparatuses, including the cop unloading apparatus and the setting apparatus, and installed on a frame pedestal, shuttle box, and thread-tying apparatus.
FIGS. 6 through 8 illustrate a grasping device for the cop-unloading apparatus.
FIG. 9 is a right side view of the cop unloading apparatus.
FIG. 10 is a right side view of a delivery apparatus located in a position for receiving a cop.
FIG. 11 is a right side view showing the delivery apparatus in the course of operation.
FIG. 12 is a front view of the delivery apparatus.
FIG. 13 is a right side view of the setting apparatus illustrated in FIG. 11 with one part thereof cut away.
FIG. 14 is a sectional view of the apparatus of FIG. 13 taken along a cutting line XIV--XIV.
FIG. 15 is a plane view of the secondary shaft and the rotating arm plate for the setting apparatus.
FIG. 16 shows a sectional view of a top portion of the setting apparatus in the proximity of a third shaft and a fourth shaft.
FIG. 17 is a front view showing a thread-tying apparatus and a new existing thread drawing apparatus at points above the shuttle race.
FIG. 18 is a sectional view, as viewed from the right side, showing the thread-tying apparatus and the shuttle draw-out apparatus installed on the shuttle race.
FIG. 19 is a schematic plane figure showing the relationship between the reel apparatus and the position of knots in the thread.
FIG. 20 is a sectional view of a reel apparatus used as a thread-adjusting apparatus for the automatic cop-replacing apparatus.
FIG. 21 is a drawing of the reel for the same reel apparatuses viewed from the shuttle race side.
FIG. 22 is a front view of an existing thread drawing apparatus used as a thread-processing apparatus.
FIG. 23 is a right side view of the thread-drawing apparatus.
FIG. 24 is a front view of a thread drawing apparatus employed as a thread-processing apparatus.
FIG. 25 is a right side view of the thread drawing apparatus of FIG. 24.
FIG. 26 is a sectional view of the base body for the thread drawing apparatus of FIG. 24.
FIG. 27 is a sectional view of FIG. 26 taken along a line XXVII--XXVII.
FIG. 28 is a sectional view of the thread-tying apparatus as viewed from the front side.
FIG. 29 is a front view of the thread-tying apparatus; FIG. 30 is a right side view of the thread-tying apparatus.
FIG. 31 is a sectional view showing a driving mechanism for a gripping claw.
FIG. 32A is a plane view of the knot of a new thread and existing thread as tied in a "single bundle knot".
FIG. 32B is a rear view of the same knot; and
FIGS. 33 through 41 are diagonal views showing the forward end part of the thread-tying apparatus, which drawings are "action-illustrative" drawings showing in sequence steps performed by the apparatus in making a "single bundle knot" of the threads.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A description will now be given with reference to FIG. 1 and subsequent figures of an automatic cop-replacing apparatus 10 constructed in accordance with the teachings of the present invention.
The loom L in this example is capable of performing hollow weaving of thick felt for use in paper making. With two types of weft accommodated inside of the two shuttles 1, the latter being reciprocated over a shuttle race 12 while a shuttle box 11 is moved upward and downward in synchronization with the shedding motion of the warp. A detailed description of the elements is, however, omitted here since they are essentially the same as in the conventional loom.
In this embodiment, the loom is provided with an automatic cop-replacing apparatus, which is operated for automatically replacing the cop in the shuttle 1 with the aim of achieving a higher working efficiency. A detailed description of the construction and operation of each of the component parts of the inventive automatic cop replacing apparatus will now be given with reference to the general diagonal view drawing in FIG. 1 and other drawings showing individual parts.
As illustrated in FIG. 1, the frame pedestal 13 is provided on one side of the shuttle race 12. In this figure, the position of the frame pedestal 13 is shown shifted in order to clearly illustrate the construction and positional relations of the various elements. ln the actual arrangement, the front side of the frame pedestal 13 in the longitudinal direction is parallel to the shuttle race 12, as shown by an arrow (a) in the figure, and the central part of the front side of the frame pedestal 13 is in a position approximately opposite to the end part of the outer side of the shuttle box 11, as illustrated also in FIG. 5.
(A) Cop-Unloading Apparatus
On the frame pedestal 13 is installed a cop-unloading apparatus (A), which takes out the cop 2 accommodated in the prescribed position and transports the same by grasping and moving its hand in directions crossing each other at right angles.
As illustrated in FIGS. 3 to 5, the frame structure 14 is installed solidly on the upper surface of the frame pedestal 13 along the longer side of the frame pedestal, this side being positioned apart from the shuttle race 12, Between the pillar members 14a of the frame structure, two guide shafts 15 are set and fixed parallel with each other. At a point midway between the two guide shafts 15, a driving screw shaft 16 is installed in parallel with the guide shafts 15 in such a manner as to permit its free rotation. One end of the screw shaft 16 is connected for interlocking motion with the motor M1 installed securely on the outer side of one pillar member 14a. On the above-mentioned guide shaft 15 is provided an X slider 17 mounted in such a manner as to permit its free sliding motion, with the screw shaft 16 meshing with the nut part 17a fixed in the center of the X slider 17. Therefore, the apparatus is constructed so that the X slider 17 moves freely in the X direction along the guide shaft 15 when the motor M1 is rotating.
Between the pillar members 14a of the frame structure 14 mentioned above, a beam member 18 is arranged fixed in the horizontal direction at a position lower than the abovementioned guide shaft 15, This beam member 18 is made of a channel bar with the channel facing upward. As illustrated in FIG. 3. is provided a cable holder 17b for protecting the cable led out of the X slider 17. In the same channel, a plural number of positioning members 19 are provided at predetermined intervals, as illustrated in FIG. 3 and FIG. 4. Also, on the lower end surface of the X slider 17, a proximity switch 20 is provided facing each positioning member 19. Thus, when the X slider 17 is to be moved, it is possible to move the X slider 17 through the prescribed length in the X direction by the use of a detection signal which the proximity switch 20 generates for each positioning member 19. Furthermore, limit switches LS1, LS2 are respectively provided on both ends of the beam member 18, these switches establishing the range of movement of the X slider 17 in the X direction.
On the above-mentioned X slider 17, two guide shafts 21 have their respective one ends set solidly in parallel to each other in the direction where they cross the above-mentioned two guide shafts 15 and the screw shaft 16 at right angles. On the other ends of the two guide shafts 21 is fixed a supporting plate 22 having a longer vertical side, and a roller 22a is set in such a way as to permit its free rolling motion on the rail member 23 provided on the frame pedestal 13 so that the roller is parallel to the frame structure 14.
At a point midway between the two guide shafts 21 mentioned above, a drive shaft 24 is provided in parallel with the guide shafts 21. The two ends of the drive shaft 24 are supported with bearings provided on the above-mentioned X slider 17 and supporting plate 22. One end of the drive shaft on the X slider 17 side projects into the area outside the X slider 17. This protruding end of the drive shaft has a pulley 25 fixed thereon, the pulley being connected with a belt 27 for interlocking motion with the output pulley 26 of the motor M2. On the above-mentioned guide shaft 21 is provided a Y-slider 28 mounted in such a way as to permit its free sliding motion. The drive shaft 24 is meshed with a nut part 28a set securely in the center of the Y slider 28. Therefore, when the drive shaft 24 is rotated by the motor M2, the Y slider 28 can move along the two guide shafts 21 in the Y direction, which crosses at right angles with the X direction, i.e., the moving direction of the X slider 17 mentioned above. As shown in FIG. 4, a connecting plate 29 is provided across and fixed between the lower end part of the supporting plate 22 and the lower end of the X slider 17 mentioned above. On the connecting plate 29 are provided a plural number of positioning members 30 at prescribed intervals. Furthermore, a proximity switch 31 is provided on the lower end surface of the Y slider 28 mounted at a point opposite the positioning members 30. It is possible to move the Y slider 28 by a prescribed length in the Y direction, using the detection signals which the proximity switch 31 generates in response to the individual positioning members 30. Also, limit switches 3LS and 4LS are provided on the ends of the connecting plate 29, these limit switches establishing the range of movement of the Y slider 28 in the Y direction.
The Y slider 28 is provided with a grasping device or the like for taking up the cop 2 and moving it upward or downward in the perpendicular direction. As shown in an enlarged view in FIGS. 6 to 8, the Y slider 28 is fitted with the barrel of the cylinder CY1 set in the vertical upsidedown position by way of a mounting jig. At the top end (i.e., the lower end) of the rod of the cylinder CY1 is fixed a mounting plate 32 bent in an "L" shape in the downward direction. On the lower portion of the mounting plate 32 is provided a driving source 33, the lower end of which is fitted with a hand, or jaws HA1 for gripping and holding the head part of the cop 2. This hand HA1 is provided with another hand HA2 by way of a pair of bars 34 so that the hand HA2 can grip and hold the rubber cap fixed at the top part of the cop 2 while holding the end part of the thread.
As illustrated in FIGS. 3 to 5, an area on the upper area of the frame pedestal 13 between the frame structure 14 and the rail member 23 is designed so as to accept the installation of containers 35 which accommodate many pieces of the cop 2. The positions for the installation of the individual containers 35 in relation to the apparatus for taking out the cop 2 are determined by the positioning plate 13a, etc., provided on the frame pedestal 13. Many short bars are hung in a matrix state on the inside bottom area of each container 35 in such a way that the intervals thereof are equal to the intervals of the arrangement of the abovementioned positioning members 19, 30, with respect to each of the X direction and the Y direction, each of said short bars 35a being inserted in a respective hole 2a in the bottom part of the cop 2, thereby holding each cop 2 in its prescribed position. In this embodiment, the hand HA1 provided on the Y slider 28 will be set directly above the cop 2, located in a position corresponding to the desired position mentioned above, when the X slider 17 and the Y slider 28 are set in their desired positions by means of the two positioning members 19, 30 and the proximity switches 20, 31. In this embodiment, moreover, different kinds of weft may be put respectively in the two shuttles, and the two containers 35 are designed so as to be capable of accommodating differentiated cops 2 with respectively different types of thread wound therearound.
With the cop-taking apparatus (A) arranged as described above, it is possible to move the hands HA1 and HA2 to the desired positions by moving the X and Y sliders 17, 28 by the driving of the two motors M1, M2 utilizing the signals from the two proximity switches 20, 31. Furthermore, it is possible to grasp and take up the head part of the desired cop 2 and to transport it for the subsequent process.
(B) Delivery Apparatus
This apparatus, provided in a position on the frame pedestal 13 between the cop-taking apparatus (A) described above and the cop-setting position to be described in (C), receives the cop 2 by grasping its bottom part as the cop 2 is brought to it, being transported with its head part grasped by the cop-taking apparatus (A), and then delivers the cop to the cop-setting apparatus (C) in the subsequent process.
As shown in FIG. 9, the barrel of the cylinder CY2 is fixed on the frame pedestal 13, with the top of the rod being directed towards a diagonally upper point. As illustrated in FIGS. 10 to 12, the base part member 36 is fixed at the top of the rod for the cylinder CY2. A plate piece part 36a of this base part member 36 is provided with an oscillating member 38 by way of the shaft member 37, and a hand HA3 is provided at the forward end of the oscillating member 38. A plate member 38a approximately triangular in shape is provided on the side of the oscillating member 38, and the other end of the spring 39, one end of which is attached to the protrusion on the inner side of the plate member 38a, is attached to the mounting piece 36b provided on the side of the plate member 38a of the base part member 36. On the upper part of the forward end of the plate piece part 36a for the base part member 36 is provided a stopper 36c having a protrusion extending towards the side of the oscillating member 38. Consequently, in a state such as that in FIG. 11 where the rod of the cylinder CY2 remains extended, the oscillating member 38 is constructed so as to be moved upward by the force of the spring 39, coming into contact with the stopper 36c, and the hand HA3 is turned in the same direction as the rod for the cylinder CY2. Also, the upper-side mounting jig 40, securing the cylinder CY2 on the frame pedestal 13, has an arm-shaped plate body 40a fixed thereon. The forward end of the plate body is provided with a cam follower 40b, which contacts the periphery of the abovementioned plate member 38a and which is installed in such a manner as to permit its free rotating motion. Accordingly, the plate member 38a comes into contact with the cam follower 40b as the rod of the cylinder CY2 is drawn into the cylinder, and performs a rotating movement in the direction in which it stretches the spring 39. It is constructed so that the oscillating member 38 and the hand HA3 move downward together with the plate member 38a in their rotational movement centering around the shaft member 37, the hand HA3 assuming a horizontal position as shown in FIG. 10 when the rod is completely drawn into the cylinder. Moreover, FIG. 41 shows an apparatus for holding down the end of the weft lest it should come apart when the hand grasps the cop.
With the delivery apparatus (B) having the construction as described hereinabove, it is possible to receive the cop 2 from the above-discussed cop-taking apparatus (A) in the position where the hand HA3 assumes its horizontal posture with the rod being drawn into the cylinder, as shown in FIG. 9, and to deliver the cop 2 to the setting position (C) (to be described later in detail) in the upper position to which the rod is extended (as shown by a dotted line).
(C) Cop-Setting Apparatus
As illustrated in FIG. 5, a setting apparatus for the cop 2 (C) is installed on the frame pedestal 13 adjacent the cop-taking apparatus (A) As FIGS. 13 and 14 indicate, the primary driving shaft 43 (hereinafter referred to as the primary shaft 43) is held by a pair of bearings 42a in such a way as to permit its free rotational motion on the mounting frame 42 installed rigidly on the frame pedestal 13. One end of the primary shaft 43 protrudes into the outer area, penetrating through one of the bearings, i e., bearing 42a. The motor M3 is installed on the frame pedestal 13 via another mounting frame 44 in a position adjacent that of the mounting frame 42. One end of the primary shaft 43 is connected for interlocking operation with the output shaft of the motor M3 by way of a joint. A base plate 46 rectangular in shape is solidly fixed via a bracket 45 to the primary shaft 43. The lower forward part and lower rear part of the base plate 46 are respectively provided with a stopper member 46a. Moreover, the mounting frame 42 mentioned above is provided with shock absorbers 47 arranged in such a way that they severally come into contact with the respective two stopper members 46a. Therefore, the base plate 46 and the members installed on the base plate 46 are constructed so that they can perform their oscillating motion within the prescribed angle range, moving around the primary shaft 43.
On the above-mentioned base plate 46 are fixed a pair of supporting blocks 48 each having a bearing. On the bearings of the supporting blocks 48, a second driving shaft 49 (hereinafter referred to as the second shaft 49) is installed in such a way as to permit its free rotational motion, the second shaft 49 being set so as to cross the above-mentioned primary shaft 43 at a right angle. The rear end of the second shaft 49 is connected for interlocking operation via a joint with the output shaft of the rotary actuator 50 installed solidly on the base plate 46 by way of the bracket 50a. The rear end of the rotary actuator 50 is provided with a proximity switch for detecting the rotational angle of the second shaft 49 and a stopper etc, for setting the range of the rotational movement of the secondary shaft 49.
As shown in FIG. 9. the second shaft 49 is designed so that it has a length sufficient for it to reach the position where the cop 2 is to be replaced on the shuttle race 12 of the loom. A housing approximately in a box shape is fixed at the forward end of the secondary shaft 49. As illustrated in FIG. 16, a shaft case 52 in a cylindrical shape is mixed on the outer wall of the housing 51 in such a manner that the secondary shaft 49 and the shaft line cross each other at a right angle. In the inside of the shaft case 52 is provided a third driving shaft 53 (hereinafter referred to as the third shaft 53) mounted by way of a pair of bearings in such a way as to permit its free rotational motion and also to prevent movement of the shaft in the axial direction. The third shaft 53 is cylindrical in shape. A boss 53a with spline thread provided on its inner circumference is inserted and fixed in the opening in the upper end of the shaft. This boss has a spline shaft 54, which serves as a fourth driving shaft (hereinafter referred to as the fourth shaft 54), inserted in it in the axial direction in such a manner as to permit its free sliding motion.
As shown in FIG. 15 and FIG. 16. a revolving arm plate 55 in the shape of a windmill with three arms 55a is mounted via a bush 56, etc., at the top of the fourth shaft 54. The revolving arm plate 55 is arranged within a plane perpendicular to the axial line of the third shaft 53 and the fourth shaft 54. On the forward end of each of the arms 55a is provided a hand HA4 constructed in such a way that it is capable of grasping the cop 2 in a posture parallel to the third shaft 53 and the fourth shaft 54. The housing 51 has a servomotor 4M mounted on its lower surface on the side opposite to the shaft case 52. The output shaft of the motor M4 is connected with the third shaft 53 by way of a joint. Therefore, by rotating the third shaft 53 and the fourth shaft, which is inserted into and connected with the third shaft 53 via a spline, it is possible to rotate the rotating arm plate 55 and each hand HA4 through a desired rotating angle. A cylinder CY3 is installed solidly on the circumferential wall of the shaft case 52 in parallel with the third shaft 53 and the fourth shaft 54. On the forward end of the rod in the cylinder CY3 is mounted a working plate 57. The forward end of the working plate 57 is fitted, in such a way as to permit its free sliding motion, into the outer circumferential channel 56a of the mounting bush 56 provided at the top of the fourth shaft 54. Accordingly, by extending or retracting the rod by the action of the cylinder CY3, it is possible to slide the fourth shaft 54 and the rotating plate arm 55 having the hand HA4 along the axial line of the shaft.
The setting apparatus (C) of this embodiment is capable of handling the cop 2 with a high degree of smoothness owing to the fact that the apparatus is equipped with proximity switches, limit switches, etc., at all important points of the various driving parts thereof, with the operating range, stopping positions, etc., for the entire apparatus being thereby determined accurately.
With the cop-setting apparatus (C) having a construction as described hereinabove, it is possible to perform such tasks as receiving the cop 2 from the above-described delivery apparatus (B) in the upper position (indicated by the imaginary line in FIG. 9) and setting a new cop 2 in the shuttle 1 in the lower position (indicated by the solid line in the same figure), or grasping and taking out the old cop.
Moreover, as shown in FIG. 1, a funnel-shaped cop chute 58 is provided at a point adjacent the setting position mentioned above, constructed so that it is possible to discard the old cop 2 taken out from the inside of the shuttle 1 by means of the setting apparatus (C).
(D) Shuttle Draw-Out Apparatus
As shown in FIGS. 1, 17 and 18, a beam member 59 is provided at a point above the shuttle race for the loom. The beam member 59 is fitted with a wall body 60 for mounting the various component devices of which the automatic cop replacing apparatus 10 is composed. As shown in FIG. 17, a box-shaped mounting frame 61 is provided via the bracket member 61a on the left part of the wall body 60. This mounting frame 61 is employed for installing a thread-tying apparatus (J) (to be described in detail under (J) below). A shuttle draw-out apparatus (D) is provided on the lower side of the mounting frame 61. This apparatus (D) is employed for drawing out onto the shuttle race 12 the shuttle 1 which has reached the shuttle box 11 after it has passed over the shuttle race 12 so that the cop may be replaced. On the lower surface of the mounting frame 61 is fixed a cylinder CY4 by way of a pair of brackets 62 in such a way that the forward end of the rod is directed towards the shuttle box 11 and the cylinder is set in parallel with the shuttle race 12. A guide bar 63 is supported, so as to permit free sliding motion, with linear bearings provided respectively at the lower ends of the brackets 62. The top of the guide bar is connected for interlocking operation with the rod of the cylinder 4CY by way of the connecting plate 64. At the lower end of the connecting plate 64, a rotary actuator 65 is installed solidly in the area opposite to the shuttle box 11, and an oscillating arm 66 is fixed on the output shaft of the rotary actuator 65, the output shaft protruding into the shuttle box 11 side after its penetration through the connecting plate 64. At the forward end of the oscillating arm 66, a suction pipe 67 is provided in parallel with the shuttle race 12. At the forward end of the suction pipe 12 is mounted a vacuum pad 67a for applying suction to and thereby holding the shuttle. At the rear end of the suction pipe 67 is provided a suction tube 67b, which is connected to and communicates with the pipe 67 and the vacuum pad 67a, making it possible to apply suction to the shuttle 1 via the vacuum pad 67a. Also, the rotary actuator 65 is provided with proximity switches for setting and detecting the rotational motion range.
The rod of the cylinder CY4 is retracted while the rotary actuator 65 swings the oscillating arm 66 upward, thereby keeping the vacuum pad 67a, etc., in a standby state in the upward position while the loom is in its normal operating condition. When the cop 2 is to be replaced, the rotary actuator swings the vacuum pad 67a, thereby bringing it down to a position directly above the shuttle race 12, extends the rod of the cylinder CY4, thereby holding the shuttle 1 in the shuttle box 11 by means of the vacuum pad 67a, and then retracts the rod of the cylinder CY4, thereby drawing out the shuttle in the box onto the shuttle race 12.
(E) Yarn Draw-Out Apparatus, etc.
As shown in FIGS. 1 and 5, a thread draw-out apparatus (E) is provided on the frame pedestal 13 adjacent the copsetting apparatus (C) described above. The thread draw-out apparatus (E) is composed of a cylinder CY5, which moves its rod in the direction perpendicular to the longitudinal direction of the shuttle race 12, and a hand HA5, which is provided at the top of the rod of the cylinder CY5. As illustrated in FIG. 19, moreover, a thread hold-down apparatus (E1) and a thread guide (E2) are provided in positions to the left and right on the peripheral part of the front end of the shuttle race 12, with the working axial line for the thread draw-out apparatus (E) forming the center. The thread hold-down apparatus (E1) has a cylinder CY6. which moves its rod in the perpendicular direction, and a hold-down plate connected to the rod of the cylinder CY6. One end of the weft at the woven fabric 69 side, which is led out of the shuttle 1 and woven into the warps on the shuttle race 12 at the time of replacement of the cop, is fixed under a holddown pressure in the space between the shuttle race 12 by means of the hold-down plate of the thread hold-down apparatus (E1). The thread draw-out apparatus (E) is constructed so that it grasps the weft 70 with its hand HA5 and draws the weft towards this side by means of the cylinder CY5. Accordingly, the thread draw-out apparatus is designed so that, as illustrated in FIG. 19, the weft 70 is held securely with the hold-down plate 68 and is at the same time supported so as to permit its free sliding motion by means of the thread guide (E2), being thereby led out in an approximately triangular shape towards this side.
The components described hereinabove are provided for the purpose of making adjustments of the knot N connecting the new weft and the existing weft, with the weft 70 wound and taken up by the reel apparatus (F) described in the following Section F.
(F) Reel Apparatus (Thread-Adjusting Apparatus)
As illustrated in FIGS. 1 and 19, a reel apparatus (F), which acts as a thread-adjusting apparatus capable of winding and taking up by a desired number of turns the weft 70 drawn out in a triangular shape towards this side by means of the thread draw-out apparatus (E), etc., is provided between the thread draw-out apparatus (E) and the thread guide (E2). As shown in FIG. 20 and FIG. 21. a hollow block body 71 is fixed, by way of a mounting jig, on a fixed loom part at a point towards this side of the shuttle race 12. On the rear end area of the block body 71 (on the side of the frame pedestal 13) is mounted a motor M5 by way of a speed reduction gear 72. Also, on the forward end area of the block body 71 (on the side of the shuttle race 12) is fixed a disc-shaped reel 73 on which a circumferential channel part 73a is formed for taking up the thread on the outer circumferential part of the reel. The output shaft 72a of the speed reduction gear 72 driven by the motor M5 is connected to one end of the revolving shaft 74 inside the block body 71, while the other end of the revolving shaft 74 protrudes from the front end side of the reel 73, being supported by a bearing 73b provided in the shaft core part of the reel 73. In the circumferential area of the protruding part of the revolving shaft 74 is formed a penetrating hole 74a extending perpendicular to the axial direction. A, guide bar 75 is inserted in the penetrating hole 74a. On one end of the guide bar 75 is fixed a hooking device for snagging the weft 70 to wind it around the reel 73. The hooking device 76 is in contact with the forward area of the reel 73. On the forward end of the reel 73, a guide channel 77 in an approximately spiral shape is formed for approximately two rounds. The guide channel 77 is composed of an outer circumferential channel 77a in a circular shape and innerside spiral channel 77b, the spiral channel 77b being continuous with the outer circumferential channel 77a . At the point of confluence of the two, a point plate 78 is mounted in such a manner as to permit its free oscillating motion. Within the guide channel 77, a member 76a, which is attached to the above-mentioned hooking device 76 so as to permit its free rotating motion, is connected for interrelated operation.
On the rear end area in the lower part of the reel 73 is fixed a suspending device for suspending the abovementioned weft 70, which is pulled around by the rotating hooking device 76. The revolving shaft 74 inside the block body 71 is provided with a detecting boss 74b, and it is constructed so that the forward end of the proximity switch 80 provided through the circumferential wall of the block body 71 is positioned counter to the detecting boss 74b, thus making it is possible to detect the rotational speed of the revolving shaft 74, i.e.. of the hooking device.
A thread guide 81 is provided along a line from the left and right side walls of the block body 71 to the upper-half part of the forward end of the reel 73. The thread guide is constructed so that it can lead the weft pulled around by the hooking device 76 into the circumferential channel part 73a on the reel 73. A tactile sensing switch 82 is provided in the vicinity of the thread guide 81, so that it is possible to directly detect the number of times the thread-winding operation is performed.
The guide bar 75 and the hooking device 76 are rotated motion when the motor is driven. With the result that the guide bar 75 can slide in relation to the penetrating hole 74a, the hooking device 76 thereafter moving in the circumferential direction with the roller member 76a guiding it into the guide channel 77. When the hooking device 76 has complete one round from the position where it started its rotational movement, the hooking device 76 can make the hook part at its forward end protrude into the outside region from the outer circumference of the reel 73, getting hold of the weft 70 as pulled out and held on the suspending device 79 and winding the same around the circumferential channel part 73a on the reel 73.
As the length of the existing weft from the end of the already woven fabric 69 to the shuttle 1 is approximately constant, the knot N formed by tying the newly supplied thread 70a and the existing thread 70b will appear repeatedly in a fixed position in the woven fabric, as illustrated under (b) in FIG. 19, with the result that such knots may occur in positions which are in succession in the warp direction as the weaving continues. This means that the fabric suffers a change in its properties in a specific place, which is a disadvantage. Therefore, if the existing thread 70 is wound with a change in the number of times of the winding operation by the use of the reel device (F) described herein, before the old cop is removed with the existing thread cut off, at the time when the cop 2 is replaced, then the positions in which the knots N formed of the wefts after the tying of the thread can be dispersed in an appropriate way to appear at different points in the woven fabric 69, as shown at (c) in FIG. 19, Also, the winding of thread after it is tied eliminates the free play which would otherwise occur on the weft in the junction between the new thread and the existing thread, making it possible to prevent such accidents as the clogging of the weft. As described below, moreover, the knows N of the thread can be led into the outside area out of a hole provided in the forward part of the shuttle 1.
(G) Shuttle Hold-Down Apparatus. etc.
As shown in FIGS. 1 and 17, the wall body 60 provided on the beam member 59 is provided with a cylinder CY7, as a shuttle hold-down apparatus (G), and a cylinder CY8, as a cop hold-down apparatus (G1). arranged side by side on the wall body by way of a bracket plate 83. These two cylinders CY7 and CY8 are positioned directly above the shuttle race 12 with their rods directed downward. When the shuttle draw-out apparatus (D) has pulled out the shuttle 1 from the shuttle box 11 onto the shuttle race 12, the setting apparatus (C) makes the existing cop in the shuttle 1 rise up to assume an upright position as illustrated in FIG. 2A, at which time the cylinder CY7 starts operating and holds down the top part of the shuttle 1 so as to prevent the shuttle 1 from being lifted up out of its place on the shuttle race 12. Moreover, when the replacement of the cop 2 is completed, the setting apparatus (C) places a new cop 2 in its horizontal position in the shuttle 1, at which time the cylinder CY8 goes into action, pushing the new cop 2 securely into the inside of the shuttle 1 by holding down the head part of the new cop 2, and then ascertaining that the new cop 2 has been placed properly in the shuttle 1, while at the same time checking the presence or absence of the cop 2.
As shown in FIG. 17, the bracket plate 83 mentioned above is provided with a thread-handling apparatus (G2). This apparatus (G2) is composed of a cylinder CY7, with the top of its rod being positioned horizontally towards the side of the thread-tying apparatus (J) (described below), and a thread-handling rod 84 provided at the top of the rod.
(H) Existing Thread Drawing Apparatus, etc., (Thread-Processing Apparatus)
As illustrated in FIGS. 1 and 17, an existing thread drawing apparatus (H), acting as a thread-processing apparatus, is provided between the thread-handling apparatus (G2) and the thread-tying apparatus (J) described above. When the existing cop 2 is to be replaced with a new one, it is necessary to tie the two wefts held on the new cop and the existing cop. For this purpose, it is necessary to cut the existing weft and, for the above-discussed setting apparatus (C), to remove the existing cop from the shuttle 1. During the time for such a handling process, and also during the period until the process for tying the new weft to the existing one is completed, the end part of the existing weft lying outside the shuttle 1 on the shuttle race 12 is held by the apparatus (H).
As shown in an enlarged view in FIG. 22 and FIG. 23, the wall body 60 is provided with a mounting bracket 85 fixed thereon, and, on the front side of this mounting bracket 85, a cylinder CY10 is installed in a perpendicular downward looking position. On the top of the rod of the cylinder CY10 is fixed a rotary actuator 86. The rotary actuator 86 is provided with a stationary arm 87 fixed on its case, and its output shaft is fitted with an oscillating arm 88. The stationary arm 87 is directed vertically towards the wall body 60 in the horizontal plane. The oscillating arm 88 is a rod body having its central part bent slightly downward for easy hooking of the weft. The oscillating arm 88 is constructed in such a manner as to permit its free oscillating motion by 90° from a position parallel to the shuttle race 12 to a position parallel to the stationary arm 87 on the horizontal plane. A suction pipe 89 is installed, in parallel with the cylinder CY10, on the back side of the bracket 85. The open lower end part of the suction pipe 89 has a pair of vertical notched channels 89a formed on its front side and back side, and it is constructed so that the central part of the oscillating arm 88 set in the vertical direction in relation to the wall body 60 can enter the suction pipe 80, being inserted through the notched channels 89a, when the rod is lifted upward by driving the cylinder CY10. A duct hose 90 is connected to the upper end of the suction pipe 89. Thus, the apparatus is constructed so that it is capable of applying suction in an upward direction and holding there the end part of the existing weft drawn into the inside of the suction pipe 89 by means of the oscillating arm 88 of the cylinder CY10.
As shown in FIG. 1, a cop guide (H1) is provided on the lower part of the existing thread drawing apparatus (H). The existing cop 2 is drawn out, together with the shuttle 1, onto the shuttle race 12 and held in an approximately vertical state by means of the setting apparatus (C). The cop guide (H1) is constructed so that the existing cop can be held in such a state by means of a pair of holding plates 91, capable of performing free oscillating motion. One of the holding plates 91 is provided with a rod-form thread guide 92 approximately in the shape of the letter S. As shown in FIG. 2A. it is constructed so that the horizontally positioned existing thread 70b is cut off, by a cutter 93 installed near the cop guide (H1), when the existing thread 70b is pulled in the horizontal direction by means of the thread guide 92, with the holding plate 91 put into its operation, after the existing thread 70b is pulled upward to form a rectangular shape by the oscillating arm 88 of the existing thread drawing apparatus (H).
(I) New Thread Drawing Apparatus (Thread-Processing Apparatus)
As shown in FIGS. 1 and 17, a new thread drawing apparatus (I), operating as a thread-processing apparatus, is installed at a point adjacent to the existing thread drawing apparatus (H) described above and between the existing thread drawing apparatus (H) and the thread-tying apparatus (J), (described hereinafter).
As illustrated in FIGS. 24 and 25, a slide rail 94 is provided on the wall body 60, and, a slide block 95 is coupled to the slide rail 94 in such a way as to permit its free movement. On the side of the slide block 95, two bracket plates 96a, 96b are mounted solidly. The top of one bracket plate 96a is connected to the rod of a cylinder CY11 rigidly mounted on the wall body 60, forming a construction capable of freely moving the slide block 95 upward and downward along the slide rail 94. On the forward end of the other bracket plate 96b, a hollow box-shaped base body 97 is mounted with a shaft bolt 97a in such a way as to enable its free oscillating movement. With the lower surface of the base body 72, a suction barrel 98 for external application to a new cop 2 to cover it in an upright position on the shuttle race 12 is connected in such a way as to define a through passage. Nozzles for high-pressure air are provided (though not illustrated in detail) in a plural number of locations on the lower end of the opening of the suction barrel 98, making it possible to pull apart by wind pressure the end part of the new thread wound around the new cop 2. With the upper surface of the base body 97, a suction duct 99 joined to a suction device (not illustrated) is connected to define a through passage, forming a construction that makes it possible to suck up a new cop 2 contained inside the suction barrel 98 and to suck the end part of the new thread into the inside region of the duct.
Furthermore, as shown in FIG. 26 nd FIG. 27, an oscillating plate 100 for cutting of the passage is provided in the inside area of the base unit 97. The oscillating shaft 101 on which the oscillating plate 100 is mounted projects beyond the base body 97. The rod of the cylinder CY12, with the barrel installed on the rod in such a way as to permit its free oscillating motion in relation to the suction duct 99, is connected to the end part of the oscillating shaft 101. Also, on the side opposite to the slide rail 94, with the suction duct 99 positioned in between, another slide plate 102 is provided. A roller 104 installed at the forward end of the arm 103 provided on the suction duct 99 is joined together with the slide plate 102 in such a way as to permit free rotational motion thereof.
This apparatus 1, constructed as described hereinabove, is designed so as to operate when a new cop 2 is set in a perpendicular state as shown in FIG. 2A in relation to the shuttle 1 pulled out on the shuttle race 12. Specifically, as illustrated in FIG. 25, the apparatus lifts the end part of the new thread upward by sucking up the new cop 2 with the suction barrel 98 externally applied over the cop and retains the new thread in the same state in preparation for the next thread-tying action, side by side with the end part of the existing thread held lifted perpendicularly upward in the neighboring section.
(J) Thread-Tying Apparatus
This apparatus is used to make a "single bundle knot" of the end part of the new thread 70a and the end part of the existing thread 70b, which are placed side by side with each other in a state in which they are lifted perpendicularly upward. A "single bundle knot" is a knot tied by tying method in which the two threads 70a, 70b, are placed together, making a ring of the threads by crossing them, and putting the part of the threads other than their ends through the ring, as illustrated in FIGS. 32A and 32B. This knotmaking method permits one easily to untie a knot by pulling the end parts of the two threads.
The present embodiment is intended for the manufacture of hollow-weave fabric for use for filter material for papermaking. In the case of hollow weave, the weft is in a state of continuum, and thus it is inconvenient for such uses to have many knots lined up in the fabric. As mentioned above, the positions of the knots N are thus intentionally dispersed in the woven fabric 69 by means of the reel apparatus described above. Furthermore, if the knots of the wefts 70 are formed by the "single bundle knot" method, it is possible to untie by hand the knots N of the wefts 70 woven into the fabric after the completion of weaving, which means that unevenness, etc., of the textile due to the knots N can be corrected.
As shown in FIGS. 1, 5, and 17, a mounting frame 61 is provided in the vicinity of the existing thread drawing apparatus (H) and the new thread drawing apparatus (I) in the area above the shuttle race 12. In the inside of this mounting frame 61, a thread-tying apparatus (J) is arranged in such a manner that the apparatus is free to perform a sliding movement in the horizontal sideways direction, A cylinder CY13 is installed rigidly, in parallel with the shuttle race 12, inside the mounting frame 61. The rod of the cylinder CY13 is connected with the thread-tying apparatus (J) and is designed to be able to advance the, entirety of the thread-tying apparatus (J) to the thread tying position at the right-hand side in the figure (i.e., a position almost immediately over the new thread drawing apparatus (I) as located in its most elevated position).
As shown in FIGS. 28 to 31, an introducing part 110a for the thread held in a rectangular shape is formed on the forward end edge of the horizontal lower surface plate 110 of the thread-tying apparatus (J), and a guide channel 110b for positioning the introduced thread 70 is formed in the rearward center of the introducing part 110a. The lower surface plate 110 has a mounting plate 111 fixed vertically approximately in its center, and supporting pillars 112 are erected in the two side areas in the forward section. The mounting plate 111 and the supporting pillar 112 are provided with an upper surface plate 113, with an introducing part 113a and a guide channel 113b of the same shape, fixed horizontally in the same position as that of the abovementioned lower surface plate 110. A shaft hole is formed in the proximity of the center of the mounting plate 111, and a cylinder-shaped guide 114 interconnected with and leading into the shaft hole is installed rigidly in a vertical position on the back surface of the mounting plate 111. The guide 114 has a slide pipe 115 inserted into it. The front end of the slide pipe 115 projects forward through the shaft hole, while its rear end projects backward from the rear end of the opening of the guide 114. A helical guide channel 116 is formed on the outer circumferential area of the slide pipe 115, and a guide pin 114a in the form of a protrusion on the inner circumferential area of the guide 114 is joined with the guide channel 116. The cylinder CY14 is, fixed on the outer circumferential area of the guide 114, and the top part of the rod of the cylinder CY14 is connected with a bush 228 provided on the rear end of the slide pipe 115 projecting rearward.
A working shaft 118 is inserted into the inside region of the slide pipe 115 in such a way as to permit its free sliding motion in the forward and backward directions. The forward and rear ends of the working shaft 118 protrude respectively from the forward and rear ends of the slide pipe 115. On the bush 117 is fixed a cylinder CY15 by way of a mounting plate 117a. The rod of the cylinder CY15 is connected with the rear end of the working shaft 118, Also, a base frame having a rectangular shape with the left side open is fixed on the front end of the slide pipe 115. Two shafts 120 are provided in parallel with each other between the upper and lower flanges 119a for the base frame. In the upper and lower positions of the two shafts 120 a total of four claw plates 121, with the tips turned inward, are installed in such a way as to permit their respective free rotational motion. The pair of claw plates 121 at the upper level and the pair of claw plates at the lower level are respectively connected with each other by means of link mechanisms for their interlocking operation, forming two pairs of grasping claws, 122, namely, upper and lower pairs. The forward end of the working shaft 118 is connected in such a way as to permit their free rotational motion, with the link mechanisms 123 connecting the two shafts 120.
As explained above, the various apparatuses are constructed in such a way that, when the cylinder CY14 is placed into its operation, the slide pipe 115 performs its sliding movement forward and backward along the guide 114 while they also are rotated and that, when the cylinder CY15 is operated, the working shaft 118 slides in relation to the slide pipe 115. actuating the two pairs of grasping claws 122 simultaneously by way of the shafts 120 and the link mechanism 123 so as to perform their opening and closing operations. That is, these apparatuses are constructed in such a manner that they are capable of getting hold of the two threads (only one of which in the figure) which pass through the upper and lower guide channels 110b, 113b and twisting them by 180°, as illustrated in FIGS. 33 to 35.
A pressing lever 124 is provided at a point below the grasping claws 122. The pressing lever 124 is connected for interlocking operation with the actuator fixed on the mounting plate 111. The lever is constructed so as to be capable of turning by 90° upward. That is, the pressing lever is constructed so as to be capable of hooking the crossing point of the thread 70 as pulled about by the grasping claws 133, 122 and pulling the thread to one side, as shown in FIG. 36.
On one side of the grasping claw 122, a hook-shaped small claw 126 and a large claw with a pressing bar 127a fixed on its top are connected coaxially, for interlocking operation, with the actuator 128 provided on the mounting plate 111. That is, the apparatus is constructed in such a way as to be capable of holding by its small claw 126 the crossing point of the thread 70 pulled to one side by the pressing lever 124, and at the same time pushing down one part of the thread 70 by the pressing bar 127a on the large claw 127.
Then, as illustrated in FIGS. 29 to 31, a gripping claw 129 is provided between the large claw 127 and small claw 126 on one side and the grasping claw 122 on the other. The sliding pipe 131 is inserted, in such a way as to permit its free movement, into the guide cylinder 130 connected from the back surface side, permitting through passage, with the shaft hole in the mounting plate 111. Inside the sliding pipe 131, a working rod 132 is installed in such a way as to permit free sliding thereof, by way of a bearing, and the rear end of the working rod is connected with the rod of a cylinder CY16 fixed on the rear end f the sliding pipe 131. A gripping claw 129, composed of a pair of claw members 129a, is installed with the shaft, in such a way as to permit its free oscillating movement, on the frame member 133 fixed on the forward end of the sliding pipe 131. The rear end part of each claw member 129a and the forward end part of the working rod 132 are connected with each other by means of a link mechanism. A cylinder CY17 is provided on the outer circumference of the guide cylinder 130. The rod of the cylinder CY17 is connected with the rear end of the sliding pipe 131. When the cylinder CY17 is placed in operation, the gripping claw 129 can as a whole move forward and backward, and, when the cylinder CY16 is operated, the gripping claw 129 can perform its opening and closing operations. As shown in FIGS. 28, 30 and 33 to 41, a thread-tightening cylinder 125 is installed on the mounting plate 111 in such a way as to permit its free forward and backward movement. On the thread-tightening cylinder 125 is provided a thread-tightening arm 125a, which is to be used for hooking and pulling the thread. That is, the apparatus, as illustrated in FIGS. 38 to 41, is constructed so that it is capable of making a "single bundle knot" of the thread 70 by a thread-tightening operation with the thread-tightening cylinder 125 operated and advanced after moving forward the gripping claw 129, grasping with the gripping claw 129 the thread 70 as pushed downward by the large claw 127, and thereafter releasing the gripping claw 122 and the small claw 126. Further, as shown in FIGS. 29 and 30, a heat cutter 134, which is to be used of cutting off any unnecessary portion of the thread 70, is provided at a point above the gripping claw 122. As illustrated in FIGS. 28 and 30, an apparatus which is to be used to hold the thread 70 inserted and passing through the upper and lower guide channels 110b, 113b and to apply the prescribed tension to these threads is provided on the inner sides of the guide channels.
In the construction described hereinabove, pressurized air is used for the source of driving power for the individual cylinders, the actuators, etc.
Next, a description will be given with regard to the working of the replacing apparatus 10, which is composed of the individual apparatuses described in the individual sections (A) to (J) hereinabove,
First, the cop 2 is taken out of the container 35 by means of the cop-taking apparatus (A). For this purpose, the X and Y sliders 17, 28 are moved along the guide shafts 15, 21, respectively, by the driving of the two motors M1, M2, and the X slider 17 and the Y slider 28 are brought to a stop in the desired positions on the basis of the detection signals which the two proximity switches 20, 31 generate for the two positioning members 19, 30. Next, the cylinder CY1 is put into operation, and the hand HA1 is moved downward and operated so as to get hold of the head part of the cop 2 located in the desired position. Then, with the cylinder CY1 and the motors M1, M2 actuated for operation the cop 2 is transported to the delivery apparatus (B).
The delivery apparatus (B) receives the cop 2 from the cop-taking apparatus (A) (in the position represented by a solid line in FIG. 9). When the hand HA3 of the delivery apparatus (B) in the horizontal state as represented in FIG. 10 has grasped the bottom of the cop 2, the above-mentioned cop-taking apparatus (A) first removes the rubber cap from the cop 2 using the, hand HA2. Thereafter, the cylinder CY2 of the delivery apparatus (B) goes into action, extending its rod. The oscillating member 38 and the hand HA3, which are placed on the top of the rod, move upward in rotational motion centered around the shaft member 37, the hand HA3 moving upward (in a diagonally upward direction) in a rectangular posture with the cop 2 held in grip. The delivery apparatus (B) hands over the cop 2 to the hand HA4 installed on the rotating arm plate 55 of the setting apparatus (C) placed in an upper position. In this embodiment, two kinds of cops 2 can be replaced with different kinds of wefts thereon. Two out of the three hands HA4 for the setting apparatus (C) should respectively grasp different kinds of cops 2 while the remaining hand HA4 should be employed of handling the existing cop 2.
When the weft 4 remaining in the shuttle 1 has been reduced to a small amount, the loom is automatically brought to a stop at the moment when the shuttle 1 has entered the inside of the shuttle box 11 after passing the shuttle race 12. First, as illustrated in FIG. 17, the shuttle draw-out apparatus goes into operation and draws out the shuttle 1 from the shuttle box 11 onto the shuttle race 12. Then, as shown in FIG. 19, the cylinder CY6 operates, and thereupon the hold-down plate 68 moves downward, fixing the weft 70 located on the side of the woven fabric 69. Also, approximately at the same time as this operation, the tread draw-out apparatus (E) goes into action, drawing out the weft towards the side in a triangular shape by means of the thread guide (E2) and the hold-down plate 68. In order to disperse the knots as discussed above, the apparatus hands over the weft to the reel apparatus (F), making an adjustment of the weft 70 by winding the existing weft by an appropriate number of times.
Then, the cop-setting apparatus (C) goes into operation. First, the motor M3 operates and moves the primary shaft 43 downward, into the state shown in FIG. 9. Then, the rotary actuator 50 operates, rotating the secondary shaft 49. That is, the secondary shaft is rotated in such a way that the rotating arm plate 55, as seen in FIG. 9, oscillates by 90° towards the side shown in the drawing, and, after this operation, the rotating arm plate 55 will be in a state where it is rectangular with respect to the horizontal plane. In this state, the hand HA4 on which the rotating arm plate 55 is located has come to a position where it is to hold in grip the head part of the existing cop 2 laid down inside the shuttle 1 (not specifically shown in the drawings). It is possible to place the existing cop 2 inside the shuttle 1 in its upright position as shown in FIG. 2A by putting the hand HA4 into operation so that it grasps the existing cop 2, and operating the rotary actuator 50 to turn by 90° in the direction reverse to that in the earlier operation while the hand holds the existing cop 2 in grip. In this case, an attempt at raising the existing cop 2 to its upright position by oscillating the hand HA4 in the upward direction would also cause the shuttle 1 to rise from the shuttle race 12 because the existing cop 2 is placed on the tong 3 located in the rear part of the shuttle 1. Therefore, as shown in FIG. 17, the shuttle hold-down apparatus (G) is put into operation approximately at the same time as this action and the part of the shuttle 1 in the proximity of its top is pressed down between the rod of the cylinder CY7 and the shuttle race 12 to keep the part secured there. In this regard, when the existing cop 2 is placed in an upright posture inside the shuttle 1, the existing thread 70b, as shown in FIG. 22, extends in a diagonal direction under tension between the existing cop 2 and the shuttle 1 (not illustrated in the figure).
Then, the existing thread drawing apparatus, which is a thread-processing apparatus, goes into action, First, the cylinder CY10 operates, and the two arms 87, 88 move downward. Then, the oscillating arm 88 rotates, and the two arms 87, 88 hold the existing thread 70b in grip. With the drawing action by the cylinder CY10, the two arms 87, 88 move upward with the existing thread 70b held thereon, entering, together with the existing thread 70b, into the interior of the suction pipe 89 via the notched channel 89a. The cop guide (H1) (shown in FIG. 1) effects an opening action of the hold-down plates 91, which have been holding down the existing cop 2, and pulls the existing thread 70b in the horizontal direction by means of the thread guide 92, as illustrated in FIG. 2A, The existing thread 70b so pulled comes into contact with a heat cutter 93 and is fused and cut off thereon by heat. The end portion of the existing thread 70b which has been cut off from the existing cop 2, is sucked into the inside of the suction pipe 89 and held in a perpendicular state by suction.
Then, the setting apparatus (C) is again operated, As mentioned above, the setting apparatus (C) at this time assumes a posture approximately as shown by the solid line in FIG. 9, and it is also in a state where it holds in grip the head part of the existing cop 2 in a perpendicular state as mounted on the shuttle 1. The cylinder CY3 is put into operation, and the fourth shaft 54 is thereby driven in the upward direction by which the rotating arm plate 55 and the hand HA4 are moved upward in the direction indicated by the arrow (d) in FIG. 13. Since the existing cop 2, which is held in grip by the hand HA4, has been brought upward, the existing cop 2 is pulled out from the tong 3 in the shuttle 1. Next, the servomotor M4 is put into motion, by which the third shaft 53 is rotated, which shaft thus causes the rotating arm plate 55 to rotate. The direction of rotation at this stage is selected depending on the point which of the new cops 2 held in grip by the hand HA4 is to be set inside the shuttle 1. The angle of rotation is approximately 120°. Specifically, the existing cop 2 is taken away from the tong 3 on the shuttle 1 and a new cop 2 is set on top of the tong 3. Then, the cylinder CY3 retracts its rod and puts a new cop 2 onto the top 3 of the shuttle 1. The hand HA4 which has held the new cop 2 in grip, opens, and, with a small amount of rotation of the servomotor M4, the hand HA4 retreats from the vicinity of the head part of the new cop 2.
The new thread drawing apparatus (I), operating as a thread-processing apparatus, goes into operation, First, the cylinder CY11 operates, whereby the suction duct 99 and the suction barrel 98, etc., are moved downward. As illustrated in FIGS. 17 and 25. The suction barrel 98 sucks the air inside it upward while enveloping the new cop 2 in an approximately perpendicular suspended state on the shuttle race 12, At that time, a plural number of nozzles provided in the proximity of the lower end of the opening in the suction barrel 98 blow out high-pressure air, thereby forming a current of air around the new cop 2 in the direction reverse to that for the winding of the thread. Consequently, the end part of the new thread 70a wound tightly around the new cop 2 is taken apart forcibly, thereafter being sucked into the duct 99 by way of the base body 97 in an upper position. When the suction barrel 98 reaches the end of its descending stroke, the cylinder CY12 goes into action, thereby setting into motion the oscillating plate 100 located inside the base body 97 and holding the end part of the new thread 70a sucking into it in a grip between the plate and the opening of the base body 97.
Then, the cylinder CY11 performs a retracting operation, whereupon the suction barrel 98, etc., grasping the new thread 70a by its end, move upward. At this time, the new thread on the new cop 2 set in the shuttle 1 is in a state of tension in the upward direction, and the end part of the existing thread drawn out of the front part of the shuttle 1 is led upward side by side with the new thread 70a. When the suction barrel 98 has reached the end of its ascending stroke, the cylinder CY12 is operated, releasing the grip by moving the oscillating plate 100 located inside the base body 97 and thereby letting the end part of the new thread 70a be subject to a suction effect.
When it is detected by a sensor (not shown) that the end part of the new thread 70a has been sucked into the barrel by an appropriate length, the servomotor M4 for the setting apparatus (C) is driven to rotate the rotating arm plate 55, the hand HA4 thereby holding down the new cop 2 by the head, preventing any excessive sucking of the thread. At the same time, the cylinder CY9 for the thread handling apparatus (G2) is operated, and the thread handling rod 84 thrusts the end parts of the new and existing threads 70a, 70b in the direction of the thread-tying apparatus (J). At the same time, the cylinder 13 operates, and the entirety of the thread-tying apparatus (J) is slid downward to a point below the new thread drawing apparatus (I). The end parts of both new and existing threads 70a, 70b are led from the upper and lower inlet sections 110a, 113a for the thread-tying apparatus (J) into the upper and lower guide channels 110b, 113b.
Then, an operation is carried out making a "single bundle knot" of both threads, i.e., the new thread and the existing thread with the thread-tying apparatus as explained with reference to FIGS. 28 to 41. (The two threads, i.e., the new one and the existing one, are represented together as if they were one thread for the sake of simplicity in FIGS. 28 to 41).
(1) First, with reference to FIG. 33, the cylinder CY15 is operated, and, by pulling the working shaft 118, the thread 70 is held in grip by means of the two pairs of gripping claws 122 and the upper and lower thread hold-down and gripping claws (not illustrated)
(2) When, with reference now to FIGS. 34 and 35, the slide pipe 115 is pulled after the cylinder CY14 is put into operation, the slide pipe 115 performs a rotating motion in the guide channel 116, being guided by the guide pin 114a. That is, the gripping claw 122 twists the thread be 180° while pulling it,
(3) Referring to FIG. 36, with the actuator operational, the pressing lever 124 is rotated upward by 90°, and the crossing point of the thread 70 pulled about by the gripping claw 122 is thrusted towards the side of the large claw 127 and the small claw 126.
(4) Upon operating the actuator 128, with reference now to FIG. 37, the small claw 126 suspends the crossing point of the thread 70, and also the pressing bar 127a of the large claw 127 pushes one of the collected threads 70 in the downward direction.
After this, the pressing lever 134 returns to the lower point.
(5) With the cylinder CY17 put into operation, the gripping claw 129 is moved forward, and the thread 70, pushed downward by the large claw 127, is held in grip by means of the gripping claw 129 by the action of the cylinder CYl6, (See FIGS. 38 and 39). The suspension of the thread 70 by means of the gripping claws 122, the large claw 127, and the small claw 126 is then released.
(6) When the cylinder 125, which is in a stand-by state in the rear part of the lower guide channel 110b, is operated the thread held by the gripping claw 129 and the gripping claw provided in the upper part of the lower guide channel 110b (not illustrated) is pushed out and the knot thereof is tightened. The two threads. i.e., the new one and the existing one, are tied together in a "single bundle knot" as illustrated in FIG. 32, and also the unnecessary portion of the threads is cut off at a point above the knot by means of the heat cutter 134, (See FIG. 40 and FIG. 41). The fragments of the upper-part thread thus cut off are sucked into the suction duct 99 and the suction pipe 89.
After the two threads, i e., the new one and the existing one, are connected with each other in the manner described above, the setting apparatus (C) goes into operation again. The rotating arm plate 55 is rotated by approximately 90° by driving the rotary actuator 50, so that the plate becomes perpendicular to the plane. In specific terms, the new cop 2 is laid down together with the tong 3, and the new cop 2 is thereby set inside the, shuttle 1.
The tied portions of both the new thread and the existing thread 70a, 70b from the top of the new cop 2 to the hole 1b in the forward part of the shuttle 1 are unnecessarily long after the thread-tying operation, and these free-play portions are liable to be caught in various structures. Therefore, approximately at the same time as the operation for laying down the new cop 2, the reel apparatus (F) is operated again, by which the weft is wound up. When the new cop 2 is set inside the shuttle 1 and the free play of the weft 70 is eliminated by the thread-winding operation with the reel apparatus (F), the cylinder CY8, operating as the cop hold-down apparatus (G1), is put into operation. Specifically, the new cop 2 is charged positively into the inside of the shuttle 1 by thrusting the head part of the new cop 2 downward by means of the top part of the rod, as illustrated in FIG. 17, and also the presence itself of the new cop 2 is checked by means of a reed sensor (not shown).
Next. The reel apparatus (F) is again operated. When the weft 70 is wound by the reel apparatus (F) around the circumferential channel part on the reel 73, the knots N of the threads come into the back side of the shuttle 1, passing through the hole 1b in the shuttle 1 because the woven fabric 69 side of the weft is fixed with the pressing plate 68. Tension in excess of what is needed may be exerted on the knot N of the thread when the knot passes through the hole 1b while the loom is being operated, and it is conceivable that the thread may be broken, depending on circumstances. Therefore, it is extremely effective, for preventing the work in progress from being interrupted, to pull the knot N out behind the shuttle 1 in advance by means of the reel apparatus (F), as in the above-described case. As mentioned also under (F). moreover, it is possible to disperse the positions of the knots N to different points on the woven fabric 69, as shown at (c) in FIG. 19, by having the reel apparatus (F) take up the existing weft 70 by an adequate amount prior to the replacement of the cop 2, making it possible to eliminate inconsistencies it the properties of the woven fabric 69 (for example, water permeability) from one point to another. Then, the motor M5 for the reel apparatus (F) is rotated in reverse by one revolution, by which the hook part at the forward end of the hooking apparatus 76, set so as to permit its free rotational motion, is moved away from the outer circumference of the reel 73 to the inner area thereof, and also the shuttle 1 is thrusted into the inside of the shuttle box 11 by means of the shuttle drawing apparatus (D). The shuttle drawing apparatus (D) is swung and moved away in the upward direction to prevent the apparatus from interfering with the shuttle 1 in its flight. Additionally, the hand HA5 for the above-mentioned thread drawing apparatus (E) is released.
After the replacement of the existing cop with a new cop is completed in the manner described hereinabove, the loom can be put into operation again.
As described above, the system in this embodiment is capable of selectively taking out a desired kind of cop stored in a prescribed position by handling it with the copunloading apparatus, and charging the new cop into the inside of the shuttle by means of the setting apparatus (C), which works independently in four directions, or taking out an existing cop from the shuttle. The system is also designed in such a way that the new and existing thread drawing apparatuses (H), (I) process the two threads, i.e., the new thread and the existing one, which are thin and hard to keep in shape, and in such a way various claw devices operated by means of cylinders can tie together the new and existing threads. Since it is possible to disperse the knots of the weft to different points by means of the reel apparatus (F), this system offers extremely great advantages in the weaving of special-purpose textiles by the hollow weave process.
As mentioned earlier, the replacing apparatus 10 is equipped with a large number of limit switches and sensors, etc., for the purpose of setting the working ranges of various members and apparatuses and detecting the amounts of work done or the positions of the various members, apparatuses, etc. Furthermore, the replacing apparatus and the loom may be provided with many detecting devices, such as limit switches, proximity switches, and sensors, other than those explicitly mentioned in the above description, in order that operating conditions may be monitored to detect problems and failures. The replacing apparatus and the loom are designed to utilize signals generated by these detecting devices and to carry out the above-described operations under control and supervision performed by the controlling and supervising system, which is an essential part of this embodiment. Thus, the system, which is a complex arrangement of a large number of equipment groups, is capable of smoothly operating the replacing apparatus and the loom, which handle various operations as an integrated system. With the replacing apparatus 10 attached to the loom in the described manner, it is possible to accomplish automation of the cop-replacing work, which could only be done manually in the past, above all, the cop-replacing work in a hollow weaving process in which continuous wefts formed by the tying of threads are woven into fabric.
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An automatic cop replacing apparatus for a shuttle-type loom with which a cop contained in the shuttle is automatically replaced, including tying the threads together of the old and new cops, and requiring no operator intervention. The apparatus includes a hand for gripping the cop, a rotary arm plate on which the hand is mounted, a drive device for rotating the rotary arm plate and for linearly moving the rotary arm plate in the axial direction with respect, thereto and a drive shaft for moving the rotary arm plate to an exchange position for the cop. A thread tying device holds and ties together the threads of the old and new cops.
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This is a continuation-in-part of United States application Ser. No. 07/308,911, filed Feb. 9, 1989, issued as U.S. Pat. No. 4,923,896 on May 8, 1990.
BACKGROUND OF THE INVENTION
The present invention relates to novel N-[substituted aryl]-N'-(substituted alkoxy)-urea and thiourea derivatives useful as pharmaceutical agents, to methods for their production, to pharmaceutical compositions which include these compounds, and a pharmaceutically acceptable carrier, and to pharmaceutical methods of treatment. More particularly, the novel compounds of the present invention prevent the intestinal absorption of cholesterol in mammals by inhibiting the enzyme acyl-coenzyme A (Acyl-CoA):cholesterol acyltransferase (ACAT).
The atheromatous plaque, which is the characteristic lesion of atherosclerosis, results from deposition of plasma lipids, mainly cholesteryl esters, in the intima of the arterial wall. Progressive enlargement of the plaque leads to arterial constriction and ultimately coronary heart disease. A number of clinical trials have shown a causal relationship between hypercholesterolemia and coronary heart disease.
Agents that control dietary cholesterol absorption moderate serum cholesterol levels. Dietary cholesterol is absorbed from the intestinal lumen as free cholesterol which must be esterified with fatty acids. This reaction is catalyzed by the enzyme acyl-CoA: cholesterol acyltransferase (ACAT). The resulting cholesteryl esters are packaged into the chylomicrons which are secreted into the lymph. Inhibitors of ACAT not only prevent absorption of dietary cholesterol but also prevent the reabsorption of cholesterol which has been released into the intestine through endogenous regulatory mechanisms, thus lowering serum cholesterol levels and ultimately counteracting the formation or development of atherosclerosis.
Copending United States Ser. No. 147,037, filed Feb. 5, 1988 now abandoned, describes certain substituted urea, thiourea, carbamate, and thiocarbamate compounds as potent ACAT inhibitors.
Copending United States Ser. No. 176,079, filed Mar. 30, 1988 now U.S. Pat. No. 5,116,848, describes certain N-[[(2,6-disubstituted)phenyl]-N'-diarylalkyl]ureas as potent ACAT inhibitors.
Copending United States Ser. No. 175,089, filed Mar. 30, 1988 now abandoned, describes certain N-[[2,6-disubstituted)phenyl]-N'-arylalkyl]ureas as potent ACAT inhibitors.
Copending United States Ser. No. 176,080, filed Mar. 30, 1988, describes certain N-2,6-dialkyl or N-2,6-dialkoxyphenyl-N'-arylalkylurea compounds as potent ACAT inhibitors.
However, the compounds disclosed in the aforementioned copending United States applications do not suggest or disclose the combination of structural variations of the compounds of the present invention described hereinafter.
SUMMARY OF THE INVENTION
Accordingly, the present invention is a novel class of compounds of Formula I ##STR1## wherein R is phenyl, phenyl mono or disubstituted with
alkyl of from one to four carbon atoms,
alkoxy of from one to four carbon atoms,
fluorine,
chlorine,
bromine,
iodine,
CO 2 R 3 wherein R 3 is alkyl of from one to four carbon atoms, or
NR 4 R 5 wherein R 4 and R 5 are independently hydrogen or alkyl of from one to four carbon atoms,
phenyl trisubstituted with fluorine, or alkoxy of from one to four carbon atoms,
naphthyl, or
naphthyl substituted with alkyl of from one to four carbon atoms
alkoxy of from one to four carbon atoms,
fluorine,
chlorine,
bromine,
iodine,
CO 2 R 3 wherein R 3 is as defined above, or
NR 4 R 5 wherein R 4 and R 5 are as defined above;
X is O or S;
R 1 is hydrogen, alkyl of from four to sixteen carbon atoms, or phenylalkyl wherein alkyl is from one to four carbon atoms;
n is 0 or an integer of 1 or 2;
R 2 is bicyclo[2.2.1]heptane, bicyclo[2.2.2]octane, ##STR2## wherein n' is an integer of 2 to 6 and R a is as defined above, ##STR3## wherein R 6 is hydrogen, alkyl of from one to eight carbon atoms or phenyl, R 7 is alkyl of from one to eight carbon atoms when R 6 is alkyl of from one to eight carbon atoms or R 7 is phenyl, and R 8 is phenyl or phenyl substituted with alkyl of from one to four carbon atoms, alkoxy of from one to four carbon atoms, fluorine, chlorine, bromine, iodine, CO 2 R 3 wherein R 3 is as defined above, or NR 4 R 5 wherein R 4 and R 5 are as defined above, or when n is 0 and R 1 is alkyl of from four to sixteen carbon atoms R 6 and R 7 are hydrogen and R 8 is as defined above, ##STR4## wherein R 9 and R 10 are independently hydrogen, alkyl of from one to four carbon atoms, alkoxy of from one to four carbon atoms, fluorine, chlorine, bromine, iodine, CO 2 R 3 wherein R 3 is as defined above or NR 4 R 5 wherein R 4 and R 5 are as defined above, and A is 0, S, SO, SO 2 , or --CH 2 --,
naphthyl or
naphthyl substituted with alkyl of from one to
four carbon atoms,
alkoxy of from one to four carbon atoms,
fluorine,
chlorine,
bromine,
iodine,
CO 2 R 3 wherein R 3 is as defined above, or
NR 4 R 5 wherein R 4 and R 5 are as defined above; or a pharmaceutically acceptable acid addition salt thereof.
Additionally, the present invention is directed to a novel method of treating hypercholesterolemia or atherosclerosis comprising administering to a mammal in need of such treatment an acyl-coenzyme A:cholesterol acyltransferase-inhibitory effective amount of a compound of Formula I in unit dosage form.
Also, the present invention is directed to a pharmaceutical composition for treating hypercholesterolemia or atherosclerosis comprising an acyl-coenzyme A:cholesterol acyl transferase-inhibitory effective amount of a compound of Formula I in combination with a pharmaceutically acceptable carrier.
Finally, the present invention is directed to methods for production of a compound of Formula I.
DETAILED DESCRIPTION OF THE INVENTION
In the compounds of Formula I, the term "alkyl" means a straight or branched hydrocarbon radical having from one to eight carbon atoms and includes, for example, methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, tertiary-butyl, n-pentyl, n-hexyl, n-heptyl, n-octyl, n-nonyl, n-decyl, undecyl, dodecyl, tridecyl, tetradecyl, pentadecyl, hexadecyl, and the like.
"Alkoxy" is O-alkyl in which alkyl is as defined above.
Certain of the compounds of Formula I are capable of further forming pharmaceutically acceptable acid addition salts. Both of these forms are within the scope of the present invention. Pharmaceutically acceptable acid addition salts are formed with inorganic and organic acids, such as, for example, hydrochloric, sulfuric, phosphoric, acetic, citric, guconic, fumaric, methanesulfonic, and the like (see, for example, Berge, S. M., et al, "Pharmaceutical Sats", Journal of Pharmaceutical Science, 66, pp. 1-19 (1977)). The acid addition salts of said basic compounds are prepared by contacting the free base form with a sufficient amount of the desired acid to produce the salt in the conventional manner. The free base form may be regenerated by contacting the salt form with a base and isolating the free base in the conventional manner. The free base forms differ from their respective salt forms somewhat in certain physical properties such as solubility in polar solvents, but otherwise the salts are equivalent to their respective free base for purposes of the present invention.
Certain of the compounds of the present invention can exist in unsolvated forms as well as solvated forms, including hydrated forms. In general, the solvated forms, including hydrated forms, are equivalent to unsolvated forms and are intended to be encompassed within the scope of the present invention.
Certain of the compounds of the present invention possess asymmetric carbon atoms (optical centers), the racemates as well as the individual enantiomers are intended to be encompassed within the scope of the present invention.
A preferred compound of Formula I is one wherein R 1 is hydrogen or alkyl of from four to sixteen carbon atoms and R 2 is ##STR5## wherein n' is an integer of 2 to 6 and R a is phenyl,
phenyl mono or disubstituted with
alkyl of from one to four carbon atoms,
alkoxy of from one to four carbon atoms,
fluorine,
chlorine,
bromine,
iodine,
CO 2 R 3 wherein R 3 is alkyl of from one to four carbon atoms, or
NR 4 R 5 wherein R 4 and R 5 are independently hydrogen or alkyl of from one to four carbon atoms,
phenyl trisubstituted with fluorine, or alkoxy of from one to four carbon atoms,
naphthyl, or
naphthyl substituted with alkyl of from one to four carbon atoms,
alkoxy of from one to four carbon atoms,
fluorine,
chlorine,
bromine,
iodine,
CO 2 R 3 wherein R 3 is as defined above, or
NR 4 R 5 wherein R 4 and R 5 are as defined above, ##STR6## where R 6 is hydrogen, alkyl of from one to eight carbon atoms or phenyl, R 7 is alkyl or from one to eight carbon atoms when R 6 is alkyl of from one to eight carbon atoms or R 7 is phenyl, and R 8 is phenyl or phenyl substituted with alkyl of from one to four carbon atoms, alkoxy of from one to four carbon atoms, fluorine, chlorine, bromine, iodine, CO 2 R 3 wherein R 3 is as defined above, or NR 4 R 5 wherein R 4 and R 5 are as defined above, or when n is 0 and R 1 is alkyl of from four to sixteen carbon atoms R 6 and R 7 are hydrogen and R 8 is as defined above, or naphthyl.
Another preferred embodiment is a compound of Formula I wherein X is 0 .
Particularly valuable are:
N-[2,6-Bis(1-methylethyl)phenyl]-N'-(diphenylmethoxy)-urea;
N-[2,6-Bis(1-methylethyl)phenyl]-N'-(triphenylmethoxy)-urea;
N-[2,6-Bis(1-methylethyl)phenyl]-N'-(1-naphthenylmethoxy)-urea; and
N'-[2,6-Bis(1-methyethyl)phenyl]-N-decyl-N-(phenylmethoxy)-urea; or a pharmaceutically acceptable acid addition salt thereof.
The compounds of the present invention are potent inhibitors of the enzyme acyl-CoA:cholesteryl acyltransferase (ACAT), and are thus effective in inhibiting the esterification and transport of cholesterol across the intestinal cell wall. Thus, the compounds of the present invention are useful in pharmaceutical formulations for the inhibition of intestinal absorption of dietary cholesterol, the reabsorption of cholesterol released into the intestine by normal body action, or the modulation of cholesterol.
The ability of representative compounds of the present invention to inhibit ACAT was measured using an in vitro test more fully described in Field, F. J. and Salome, R. G., Biochimica et Biophysica Acta, volume 712, pages 557-570 (1982). The test assesses the ability of a test compound to inhibit the acylation of cholesterol by oleic acid by measuring the amount of radio-labeled cholesterol oleate formed from radio-labeled oleic acid in a tissue preparation containing rabbit intestinal microsomes. The data in Table I is expressed as IC 50 values, i.e., the concentration of test compound required to inhibit cholesteryl oleate formation to 50% of control. The data in the table shows the ability of representative compounds of the present invention to potently inhibit ACAT.
TABLE 1______________________________________Biological Activity of Compounds of Formula IExample IC.sub.50Number Compound (μ moles)______________________________________1 N-[2,6-Bis(1-methylethyl)phenyl]- 0.030 N'-(diphenylmethoxy)-urea2 N-[2,6-Bis(1-methylethyl)phenyl]- 0.053 N'-(triphenylmethoxy)-urea3 N-[2,6-Bis(1-methylethyl)phenyl]- 0.092 N'-(1-naphthalenylmethoxy)-urea______________________________________
A compound of Formula I ##STR7## wherein R is phenyl, phenyl mono or disubstituted with
alkyl of from one to four carbon atoms,
alkoxy of from one to four carbon atoms,
fluorine,
chlorine,
bromine,
iodine,
CO 2 R 3 wherein R 3 is alkyl of from one to four carbon atoms, or
NR 4 R 5 wherein R 4 and R 5 are independently hydrogen or alkyl of from one to four carbon atoms,
phenyl trisubstituted with fluorine, or alkoxy of from one to four carbon atoms,
naphthyl, or
naphthyl substituted with alkyl of from one to four carbon atoms alkoxy of from one to four carbon atoms,
fluorine,
chlorine,
bromine,
iodine,
CO 2 R 3 wherein R 3 is as defined above, or
NR 4 R 5 wherein R 4 and R 5 are as defined above;
X is O or S;
R 1 is hydrogen, alkyl of from four to sixteen carbon atoms, or phenylalkyl wherein alkyl is from one to four carbon atoms;
n is 0 or an integer of 1 or 2;
R 2 is bicyclo[2.2.1]heptane, bicyclo[2.2.2]octane, ##STR8## wherein n' is an integer of 2 to 6 and R is as defined above, ##STR9## wherein R 6 is hydrogen, alkyl of from one to eight carbon atoms or phenyl, R 7 is alkyl of from one to eight carbon atoms when R 6 is alkyl of from one to eight carbon atoms or R 7 is phenyl, and R 8 is phenyl or phenyl substituted with alkyl of from one to four carbon atoms, alkoxy of from one to four carbon atoms, fluorine, chlorine, bromine, iodine, CO 2 R 3 wherein R 3 is as defined above, or NR 4 R 5 wherein R 4 and R 5 are as defined above, or when n is 0 and R 1 is alkyl of from four to sixteen carbon atoms R 6 and R 7 are hydrogen and R 8 is as defined above, ##STR10## wherein R 9 and R 10 are independently hydrogen, alkyl of from one to four carbon atoms, alkoxy of from one to four carbon atoms, fluorine, chlorine, bromine, iodine, CO 2 R 3 wherein R 3 is as defined above or NR 4 R 5 wherein R 4 and R 5 are as defined above, and A is 0, S, SO, SO 2 , or --CH 2 --,
naphthyl or
naphthyl substituted with alkyl of from one to four carbon atoms,
alkoxy of from one to four carbon atoms,
fluorine,
chlorine,
bromine,
iodine,
CO 2 R 3 wherein R 3 is as defined above, or
NR 4 R 5 wherein R 4 and R 5 are as defined above; or a pharmaceutically acceptable acid addition salt thereof is prepared by reacting a compound of Formula II ##STR11## wherein R 1 , R 2 , and n are as defined above with a compound of Formula III
R--N═C═X III
wherein R and X are as defined above in a solvent such as, for example, ethyl acetate and the like to give a compound of Formula I.
A compound of Formula IIb ##STR12## wherein R 11 is alkyl of from four to sixteen carbon atoms or phenylalkyl wherein alkyl is from one to four carbon atoms and R 2 and n are as defined above, is prepared by reacting a compound of Formula IIa
H.sub.2 N--O--(CH.sub.2).sub.n --R.sub.2 IIa
wherein R 2 and n are as defined above with a compound of Formula IV
R.sub.11 --HAL IV
wherein HAL is bromine or chlorine and R 11 is as defined above in the presence of a base such as, for example, sodium hydroxide, sodium carbonate, sodium bicarbonate, potassium hydroxide, potassium carbonate, potassium bicarbonate, and the like to give a compound of Formula IIb.
Additionally, a compound of Formula Ia ##STR13## wherein R 11 is alkyl of from four to sixteen carbon atoms or phenylalkyl wherein alkyl is from one to four carbon atoms and R, R 2 , X, and n are as defined above may be prepared by reacting a compound of Formula I wherein R 1 is hydrogen and R, R 2 , X, and n are as defined above with a compound of Formula IV and a base such as, for example, sodium hydride and the like in the presence of a solvent such as, for example, dimethylformamide and the like using the methodology described by Sulsky, R. and Demers, J. P., Tetrahedron Letters, Volume 30, pages 31-34 (1989) to give a compound of Formula Ia.
A compound of Formula IIa is either known or may be prepared using the methodology described by A. F. McKay, et al., Canadian Journal of Chemistry, Volume 38, pages 343-358 (1960), E. L. Schumann, et al, Journal of Medicinal Chemistry, Volume 7, pages 329-334 (1964), and P. Mamalis, et al, Journal of the Chemical Society, pages 229-238 (1960).
A compound of Formula III or Formula IV is either known or capable of being prepared by methods known in the art.
The compounds of the present invention can be prepared and administered in a wide variety of oral and parenteral dosage forms. It will be obvious to those skilled in the art that the following dosage forms may comprise as the active component, either a compound of Formula I or a corresponding pharmaceutically acceptable salt of a compound of Formula 1.
For preparing pharmaceutical compositions from the compounds of the present invention, pharmaceutically acceptable carriers can be either solid or liquid. Solid form preparations include powders, tablets, pills, capsules, cachets, suppositories, and dispersible granules. A solid carrier can be one or more substances which may also act as diluents, flavoring agents, solubilizers, lubricants, suspending agents, binders, preservatives, tablet disintegrating agents, or an encapsulating material.
In powders, the carrier is a finely divided solid which is in a mixture with the finely divided active component.
In tablets, the active compound is mixed with the carrier having the necessary binding properties in suitable proportions and compacted in the shape and size desired.
The powders and tablets preferably contain from five or ten to about seventy percent of the active compound. Suitable carriers are magnesium carbonate, magnesium stearate, talc, sugar, lactose, pectin, dextrin, starch, gelatin, tragacanth, methylcellulose, sodium carboxymethylcellulose, a low melting wax, cocoa butter, and the like. The term "preparation" is intended to include the formulation of the active compound with encapsulating material as a carrier providing a capsule in which the active component, with or without other carriers, is surrounded by a carrier, which is thus in association with it. Similarly, cachets and lozenges are included. Tablets, powders, capsules, pills, cachets, and lozenges can be used as solid dosage forms suitable for oral administration.
For preparing suppositories, a low melting wax, such as a mixture of fatty acid glycerides or cocoa butter, is first melted and the active component is dispersed homogeneously therein, as by stirring. The molten homogeneous mixture is then poured into convenient sized molds, allowed to cool, and thereby to solidify.
Liquid form preparations include solutions, suspensions, and emulsions, for example, water or water propylene glycol solutions. For parenteral injection liquid preparations can be formulated in solution in aqueous polyethylene glycol solution.
Aqueous solutions suitable for oral use can be prepared by dissolving the active component in water and adding suitable colorants, flavors, stabilizing and thickening agents as desired.
Aqueous suspensions suitable for oral use can be made by dispersing the finely divided active component in water with viscous material, such as natural or synthetic gums, resins, methylcellulose, sodium carboxymethylcellulose, and other well-known suspending agents.
Also included are solid form preparations which are intended to be converted, shortly before use to liquid form preparations for oral administration. Such liquid forms include solutions, suspensions, and emulsions. These preparations may contain, in addition to the active component, colorants, flavors, stabilizers, buffers, artificial and natural sweeteners, dispersants, thickeners, solubilizing agents, and the like.
The pharmaceutical preparation is preferably in unit dosage form. In such form, the preparation is subdivided into unit doses containing appropriate quantities of the active component. The unit dosage form can be a packaged preparation, the package containing discret quantities of preparation, such as packeted tablets, capsules, and powders in vials or ampoules. Also, the unit dosage form can be a capsule, tablet, cachet, or lozenge itself, or it can be the appropriate number of any of these in packaged form.
The quantity of active component in a unit dose preparation may be varied or adjusted from 50 mg to 1500 mg preferably 200 mg to 500 mg according to the particular application and the potency of the active component. The composition can, if desired, also contain other compatible therapeutic agents.
The dosage range for a 70-kg mammal is from about 1 mg/kg to about 100 mg/kg of body weight per day or preferably about 3 mg/kg to about 15 mg/kg of body weight per day when the compounds of the present invention are used therapeutically as antihypercholesterolemic and antiatherosclerotic agents. The dosages, however, may be varied depending upon the requirements of the patient, the severity of the condition being treated, and the compound being employed. Determination of the proper dosage for a particular situation is within the skill of the art. Generally, treatment is initiated with smaller dosages which are less than the optimum dose of the compound. Thereafter, the dosage is increased by small increments until the optimum effect under the circumstances is reached. For convenience, the total daily dosage may be divided and administered in portions during the day if desired.
The following nonlimiting examples illustrate the inventor's preferred methods for preparing the compounds of the invention.
EXAMPLE 1
N-[2,6-Bis(1-methylethyl)phenyl]-N'-(diphenylmethoxy)-urea
To a solution of 1,1-diphenylmethoxyamine (0.9 g, 0.0045 mol) (E. L. Schumann, et al, Journal of Medicinal Chemistry, Volume 7, pages 329-334 (1964)) in 20 ml of ethyl acetate is added 2,6-diisopropylphenyl isocyanate (0.91 g, 0.0045 mol) and the reaction mixture is stirred for 20 hours at room temperature. The volatiles are removed under reduced pressure and the residue treated with 30 ml hexane-ethyl acetate (4:1). The precipitated solid is filtered and dried affording 1.45 g of N-[2,6-bis(1-methylethyl)phenyl]-N'-(diphenylmethoxy)-urea; mp 152°-154° C.
In a process analogous to Example 1 using appropriate starting materials, the corresponding compounds of Formula I are prepared:
EXAMPLE 2
N-[2,6-Bis(1-methylethyl)phenyl]-N'-(triphenylmethoxy)urea; mp 198°-200° C.
EXAMPLE 3
N-[2,6-Bis(1-methylethyl)phenyl]-N'-(1-naphthalenylmethoxy)-urea; mp 128°-130° C.
EXAMPLE 4
N'-[2,6-Bis(1-methylethyl)phenyl]-N-decyl-N-(phenylmethoxy)-urea
STEP A: Preparation of N-[2,6-Bis(1-methylethyl)-phenyl]-N'-(phenylmethoxy)-urea
O-Benzylhydroxylamine is prepared by adding 6 g of O-benzylhydroxylamine hydrochloride to 50 ml of a 25% solution of sodium hydroxide in water and extracting with ethyl acetate (3×100 ml). The combined ethyl acetate extracts are washed with water and dried over magnesium sulfate. The colorless oil which remained after filtration and concentration (3.4 g, 27.6 mmol) is dissolved in 25 ml of ethyl acetate and 6 ml of 2,6-diisopropylphenyl isocyanate (90%) in 5 ml of ethyl acetate is added dropwise under nitrogen. The mixture is stirred overnight at room temperature, filtered, concentrated and the solid residue triturated with isopropyl ether. Filtration afforded 5.24 g of N-[2,6-bis(1-methylethyl)phenyl]-N'-(phenylmethoxy)-urea as a colorless solid; mp 136°-138° C. A second crop of 3.9 g is also isolated; mp 136°-138° C.
STEP B: Preparation of N'-[2,6-Bis(1-methylethyl)-phenyl]-N-decyl-N-(phenylmethoxy)-urea
A solution of N-[2,6-bis(1-methylethyl)phenyl]-N'-(phenylmethoxy)-urea (1.62 g, 5 mmol) in 5 ml of dry dimethylformamide is added dropwise to a room temperature suspension of hexane washed sodium hydride (0.13 g, 5.5 mmol) in 3 ml of dry dimethylformamide with stirring. When gas evolution is complete, the suspension is warmed to 60° C. and 1-bromodecane (1 ml, 5 mmol) is added dropwise. The mixture is stirred for 30 minutes, cooled to room temperature, poured into water and extracted with diethyl ether. The diethyl ether extract is diluted with hexane and washed with water, dried, filtered, and evaporated to provide a colorless solid which is triturated with hexane to give 1.47 g of N'-[2,6-bis(1-methylethyl)phenyl]-N-decyl-N-(phenylmethoxy)-urea; mp 91°-93° C.
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Novel N-[substituted aryl]-N'-(substituted alkoxy)-urea and thiourea derivatives are described, as well as methods for the preparation and pharmaceutical composition of same, which are useful in preventing the intestinal absorption of cholesterol and thus are useful in the treatment of hypercholesterolemia and atherosclerosis.
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FIELD OF THE INVENTION
The present invention relates to the field of cosmetology and dermatology, and has for its object the use for cosmetic, dermatologic or pharmaceutical applications, of a plant extract of the genus Adansonia, more particularly of the species Adansonia digitata ( baobab ), as well as a cosmetic and/or pharmaceutical product or composition for the skin and/or the hair, eyelashes or nails, comprising such an extract.
BACKGROUND OF THE INVENTION
Baobab ( Adansonia digitata ) is a deciduous tree, coming from the dry parts of central Africa and appears mostly in tropical countries, principally as a component of secondary forests.
The origin of plants of the genus Adansonia is probably located in Madagascar where several endemic species have been described and where Adansonia digitata also exists. Other species of the mentioned genus have been found in east Africa and in Australia.
The different constituent parts of baobab were and still are used and exploited in Africa, either from an economic standpoint (the bark for the production of fibers and paper, the wood has a rubber coagulant and the roots as a red coloring material), or as food (more particularly seeds and young leaves) or again as medicine (the bark has astringent diaphoretic and even febrifugic properties; the wood and the seeks have antidysenteric and anti-inflammatory properties; the leaves are used as an antiperspirant, against kidney and bladder troubles and as an anti-asthmatic and emollient).
It is known that the leaves contain particularly mucilages which swell in the presence of water.
Baobab leaves (D. YAZZIE et al., Journal of Food Composition and Analysis, 1994, 7; 3, 198-193 13 R. GAIWE et al., International Journal of Crude Drug Research, 1989, 27, 2, 101-104) contain, in addition to mucilages, mineral salts, proteins, catechic tannins and vitamin compounds (riboflavin, thiamine, vitamin C, niacin); a flavonoid-type compound has also been discovered.
Analysis of the amino acid composition indicates that the proteins of the leaves of baobab , which represent about 10.6% of the dry weight of the leaves, contain interesting quantities of the following essential amino acids: lysine, arginine, threonine, tyrosine, phenylalanine, tryptophane, methionine and cysteine.
These leaves constitute quantitatively and qualitatively a good source of food proteins.
Moreover, baobab leaves contain high quantities of calcium (3.07 to 30 mg/g of dry leaves) and substantial quantities of iron, potassium, magnesium, manganese, molybdenum, phosphorus and zinc.
The dry extractable mucilage content of the leaves varies and is of the order of 9 to 12% relative to the dry leaves, the principal constituents of these mucilages having molecular weights higher than 100,000.
A high interaction between the proteins and the polysaccharides is supposed.
According to the literature (M. L. WOOLFE et al., J. Sci. Fd. Agric., 1977, 28, 519-529), the chemical composition of the mucilages of baobab leaves has been established as follows:
40.2 g galacturonic acid/100 g of mucilages
39.1 g glucuronic acid/100 g of mucilages
9.3 g of neutral sugars/100 g of mucilages.
These neutral sugars, which are rhamnose, galactose, glucose and arabinose, are present in a mole ratio of 0.6-1-0.44-0.15.
The above data indicate a very high portion of uronic acids and few neutral sugars: these mucilages do not have pectic compounds or pectic type units.
Moreover, these mucilages have interesting rheologic properties, their viscosity decreasing with an increase in the temperature of extraction.
SUMMARY OF THE INVENTION
However, the inventor of the present invention has determined, in an unexpected and surprising manner, that the extracts of plants of the Adansonia type, and more particularly extracts enriched in mucilages, have immediate properties more varied and quantitatively substantially greater than those of the polysaccharides already used in cosmetology or pharmacology, as well as long term effects and finally a very high tolerance.
OBJECTS OF THE INVENTION
Thus, the principal object of the present invention consists in the use or application of at least one extract of a plant of the genus Adansonia belonging to the family of Bombacaceaes for the preparation of a cosmetic and/or pharmaceutical product for topical use for the skin and/or the hair, eyelashes and nails.
DETAILED DESCRIPTION OF THE INVENTION
Preferably, the extract used is an extract of a plant belonging to the species selected from the group comprised by Adansonia digitata, Adansonia fony, Adansonia gregorii, Adansonia madagascariensis, Adansonia grandidieri, Adansonia suarezensis and Adansonia za.
According to a preferred embodiment of the invention, the mentioned extract is obtained from fresh or dried leaves (for example reduced to powder), preferably of Adansonia digitata or baobab , the extraction being carried out according to conventional extraction techniques, such as hot or cold extraction, with a solvent selected from the group consisting of water, aqueous solutions (neutral, acidified or alkaline), alcohols and mixtures of two or several of the mentioned solvents.
According to a first modification of embodiment of the invention, the extract used is a total extract of leaves, particularly of baobab, containing all the active ingredients contained in said leaf.
This total extract can be dried by techniques known to those skilled in the art such as lyophilization or atomization.
According to a second modified embodiment of the invention, it is possible to proceed with supplemental operations of purification (for example by precipitation in organic solvents) permitting to obtain on the one hand an extract consisting of one or more purified mucilages or an extract enriched in mucilages obtained from leaves, particularly of baobab , and/or, on the other hand, an extract consisting of a co-product of the extraction and/or purification of mucilages from leaves, particularly baobab , said co-product constituting a directly usable fraction rich in flavonoids, mineral salts, proteins, vitamins and/or other like compounds, such as particularly tannins.
It has also been discovered, in an unexpected and surprising manner, that when the process of extraction or purification comprises a step of treatment with a glycolytic enzyme of the β-glycosidase type, the mucilage or mucilages or extract rich in mucilage or mucilages that results has increased stability in solution.
By way of non-limiting example, there will hereafter be described different possible processes for obtaining an extract of baobab , particularly mucilages, which can be used within the scope of the present invention.
EXAMPLE 1
(production of type I extract)
2.2 Kg of leaves of Adansonia digitata are crushed in a bladed crusher and pass through a screen of 5 mm, 2.00 kg of leaf powder are thus obtained.
In a vat provided with an agitator, there is introduced 20.00 kg of distilled water and then the following operations are successively carried out:
raising the temperature to about 70° C.,
introducing with agitation the 2.00 kg of crushed and screened leaves,
increasing the temperature to 90-95° C.,
extracting for one hour with agitation,
cooling,
centrifuging for 10 minutes at 5,000 g,
recovering the supernatant (15.4 liters) which has a viscous appearance, a brown color and comprises 2.6% by weight of dry extract.
Purified mucilages can be obtained by using the following treatments of the above supernatant:
precipitating mucilages by addition of the supernatant with vigorous agitation, into 0.6 volume of absolute ethanol; formation of fibers which wind up about the agitator and hydroalcoholic supernatant brown in color,
letting stand 2 hours in this medium,
recovering the fibers, drying them on a filter cloth,
washing the polysaccharide fibers in 1.6 liters of acetone (this treatment can be repeated),
drying the fibers, spreading them out and drying them in open air then in an oven at 50° C.,
comminuting the dry mucilages in a bladed comminutor.
The weight of mucilage obtained is 168 grams, namely a yield of Y=8.4% by weight relative to the crushed leaves and a yield of about 7.6% by weight relative to the whole leaves (with stems).
EXAMPLE 2
(production of type 2 extract)
In a vat provided with an agitator, there is introduced 25.00 kg of distilled water and the following operations are successively carried out:
the temperature is raised to about 70° C.,
there are introduced with agitation 2.00 kg of crushed and screened leaves with vigorous agitation,
the temperature is raised to 90-95° C.,
extraction with stirring is carried out for an hour,
cooling,
centrifuging for 10 minutes at 5,000 g,
collecting the supernatant (16.9 liters) which has a viscous appearance, brown color and comprises 2.3% by weight of dry extract,
holding the supernatant at 4° C. for hydrolysis.
A determination of the mucilage content of the solution can be carried out by precipitation of 200 ml of supernatant in a volume of ethanol, washing in acetone and drying the obtained precipitant. The concentration of mucilage in the extract thus determined is 9.15 g/l, namely a yield of mucilage Y=7.7% by weight relative to the powder of crushed leaves.
Purification of the mucilage of the extract obtained above can be carried out by using the following steps:
placing the viscous extract in a reactor provided with a pH electrode,
adjusting the pH of the solution to 5.0,
increasing the temperature to 25° C.,
adding to the solution an enzyme of the glucanase type at a dosage level of 10% relative to the mucilage, determined by alcoholic precipitation,
hydrolyzing for 5 hours at a temperature of 50-55° C. and a pH of about 5.0,
inactivating the enzyme by heating for 20 minutes at 100° C.,
cooling to ambient temperature,
centrifuging,
collecting the supernatant (14.73 liters),
precipitating the mucilage by addition of the supernatant with violent agitation into one volume of absolute ethanol,
treating the precipitate according to Example 1.
The weight of mucilage recovered is 132.7 grams, namely a yield of Y=6.6% by weight relative to the initial crushed leaves.
EXAMPLE 3
(production of type 3 extract)
There is filtered 1.9 liter of hydroalcoholic supernatant obtained from the precipitation of mucilage in Example 2 (dry extract=1.1%) on a clarifying filter 0.5 μm.
The theoretical yield in raw material (taking account of the dry extract and of the total volume of hydroalcoholic supernatant) is 7.76%/powder of leaves.
The following supplemental treatments are then applied to the filtered supernatant:
evaporation of the alcohol of the extract with a rotating evaporator (temperature of 40° C.),
obtaining 0.91 liter of aqueous phase with a dry extract of 2.2%,
if desired, addition of 40 g of dehydration adjuvant,
atomization or lyophilization,
obtention of 39.9 g of atomisate, namely an atomization output of 66.5%.
Testing for the presence of flavonoid compounds in the above product according to a known process (H. WAGNER et al., Plant Drug Analysis, p. 172, Springer Verlag 1984), carried out by use of the following migration solvents: ethyl acetate/formic acid/glacial acetic acid/water (100/11/11/27).
The detection of flavonoids is carried out with diphenyl-boric-acid-2-amino-ethyl ester of 1% in methanol/PEG 4000 of 5% in absolute ethanol.
Reading is carried out with a UV lamp, 365 nm.
It displays in the co-product a compound of orange color after vaporization of the reagent and observation at 365 nm whose Rf (0.39) is near that of rutine (0.40).
There are also observed 4 pockets of orange, blue and yellow color whose Rf are comprised between 0.095 and 0.18.
The present invention also has for its object cosmetic and/or pharmaceutical products or compositions for the skin and/or the hair, eyelashes and nails, characterized in that it comprises between 0.01% and 50.00% by weight of a plant extract of the genus Adansonia, particularly baobab.
Preferably, these products consist of a treatment compound comprising between 0.01% and 20.00% by weight of extract, particularly extract of leaves of baobab.
In these compositions or products for care of the skin, hair, eyelashes and nails, the mucilages, proteins and mineral salts extracted from plants of the genus Adansonia, and particularly baobab , have been preferably used as active emollients, softeners, insulators, repairers, hydrators, soothers, elastifiers, nutrients and regenerators of barrier properties.
The flavonoid co-products can be used in skin and hair care products as active vitamin P factors, anti-free radicals, and local anti-inflammatories, soothing agents, protectors, photoprotectors against UVB and UVA, anti-pollutants, anti-toxics, anti-sensitive skin and inhibitors of enzymes such as: elastase, hyaluronidase, histidine decarboxylase, phosphodiesterase of AMPC, lipo-oxygenase, tyrosinase or the like.
These complete active extracts of a plant of the Adansonia type (particularly baobab ), in which the active purified transformed fractions such as mucilages, proteins, flavonoids, calcic mineral compounds or the like, can be present in the form of anhydrides, in the form of aqueous solutions or hydroglycolides, or again in time-released galenic form or with different actions (liposomes, nanosphere, microspheres, microcapsules or the like).
The extracts according to the invention are adapted to be incorporated in the most diverse cosmetic and/or pharmaceutical forms, such as particularly lotions, gels, hydrogels, oil/water emulsions, water/oil emulsions, micro-emulsions, skin care products, capillary care products or the like.
To demonstrate the beneficial effects of the extracts of leaves of Adansonia according to the invention, and more particularly those of the co-product of purification of the mucilages not only as to cosmetics but also as to biologics, the inventor has carried out various “in tubo” and “in vitro” tests of such a leaf extract (hereinafter called 114-I) obtained by means of the process described in the above Example 3.
The objects sought, the operative modes used and the results obtained within the scope of these tests are set forth briefly in what follows.
I) Anti-Free Radical Tests “in tubo”
The anti-free radical capacities are evaluated by a battery of tests covering not only the initial radical forms but also the reactive forms of oxygen (HO o and O{overscore ( 2 o +L )}) induced in vivo.
Anti-DPPH Test:
DPPH (diphenylpicryl-hydrazyl) is a stable-free radical and colored violet, which is transformed to its leucoderivative by substances which capture and neutralize free radicals (=so-called “scavenger” effect).
In this test, the optical density is measured at 513 nm.
Results (average of 2 tests):
Amount of Leucoderivative Formed
Doses in % (w/v)
(in %/Sample)
Sample
0
114-1 at 0.003%
28 C150 = 0.0124% (w/v)
114-1 at 0.03%
91
114-1 at 0.3%
100
Anti-HO o Test with Salicylic Acid:
HO o (formed by H 2 O 2 in the presence of Fe++ and EDTA) is shown by salicylic acid.
Salicylic acid is hydroxylated by HO o into a pink compound and the quantity of hydroxylated salicylic acid corresponds to the optical density at 490 nm.
Results (average of 2 tests):
Doses in % (w/v)
Amount of Hydroxylation with EDTA
Sample
100
114-1 at 0.03%
92 C150 = 0.24% (w/v)
114-1 at 0.3%
38
Anti-HO o Test with Desoxyribose
HO o (formed by H 2 O 2 in the presence of Fe++ and EDTA) is disclosed by desoxyribose (this so-called Fenton reaction is also carried out without EDTA to measure the capacity to complex iron).
Desoxyribose is oxidized by HO o into andehydic derivatives measured with thiobarbituric acid, thiobarbituric acid forming by condensation with the aldehydes a roseate compound (optical density measured at 532 nm)
Results (average of 2 tests):
Doses in
Aldehyde formed
Aldehyde formed
% (w/v)
with EDTA
without EDTA
Sample
100
100
114-1 at 0.03%
99 C150 = 0.33% (w/v)
76 C150 = 0.16% (w/v)
114-1 at 0.3%
55
21
Anti-Superoxide anion Tests O{overscore ( 2 o +L )}
O{overscore ( 2 o +L )} is produced by an enzyme induced during oxidative stress: xanthine oxidase, which catabolizes the puric bases (adenine, guanine) in uric acid and O{overscore ( 2 o +L )}.
Then O{overscore ( 2 o +L )} disassociates spontaneously (or by SOD=superoxide dismutase) into H 2 O 2 and O 2 .
Results (average of 2 tests):
a) O{overscore ( 2 o +L )} displays luminescence with luminol
Doses in % (w/v)
% Inhibition of Luminescence/Sample
Sample
0
114-1 at 0.0003%
10 C150 = 0.0011% (w/v)
114-1 at 0.003%
67
114-1 at 0.03%
99
b) O{overscore ( 2 o +L )} and H 2 O 2 disclosed by luminol in the presence of microperoxidase
Doses in % (w/v)
% Inhibition of Luminescence/Sample
Sample
0
114-1 at 0.003%
13 C150 = 0.0096% (w/v)
114-1 at 0.03%
62
c) O{overscore ( 2 o +L )} and H 2 O 2 disclosed by NBT (tetrazolium salt) (optical density measured at 540 nm)
Doses in % (w/v)
% Inhibition of DO at 540 nm/Sample
Sample
0
114-1 at 0.03%
21 C150 = 0.1298% (w/v)
114-1 at 0.3%
67
II) Anti-UVA Cytoprotection of Human Fibroblasts, “in vitro” Survival
UVA penetrates the skin where it induces an oxidative stress characterized by lipoperoxidation of the cytoplasmic membranes.
The lipoperoxides break down into malonaldialdehyde which cross-links numerous biological molecules as proteins (inhibition of enzymes) and nucleic bases (mutagenesis).
To carry out the tests, the fibroblasts are seeded into a culture medium comprises fetal veal serum and the product 114-1 (in the medium defined with 2% serum) is added 72 hours after seeding.
After an incubation of 48 hours at 37° C. and CO 2 =5%, the culture medium is replaced by a saline solution and the fibroblasts are irradiated with a dose of UVA (15 J/cm 2 ; tubes of the MAZDA FLUOR TFWN40 type).
At the end of irradiation, the quantity of MDA (malonaldialdehyde) is added to the supernatant saline solution and the quantity of proteins is measured in the fibroblasts.
The MDA is measured by the reaction with thiobarbituric acid and the proteins according to the so-called Bradford method.
Results (in % relative to the sample, the average of 2 tests, each in triplicate):
Doses in % (w/v)
MDA
Proteins
Non-irradiated sample
0
100
Irradiated sample (UVA)
100
65
Medium + 114-1 at 0.005%
60
61
Medium + 114-1 at 0.010%
45
59
III) Anti-UVB Cytoprotection on Human Keratinocytes Surviving “in vitro”
UVB triggers an inflammation (erythema, edema) by activation of an enzyme, namely phospholipase A2 or PLA2, which loosens arachidonic acid of phospholipids from the plasmic membrane.
Arachidonic acid is the precursor of prostaglandines which are mediators of inflammation, the prostaglandines E2 (=PGE2) being formed by cyclooxygenase.
To carry out the tests, keratinocytes are seeded into a medium of fetal veal serum and the product 114-1 (diluted in saline solution) is added 72 hours after seeding.
Immediately, the keratinocytes are irradiated with a dose of UVB (30 mJ/cm 2 —tubes of the DUKE FL40E type).
After an incubation of 1 day at 37° C., CO 2 =5%, the quantities of PGE2 and LDH are measured in the supernatant medium.
The number of adherent keratinocytes is determined (after trypsination) by a particle counter.
The quantity of PGE2 is determined by an ELISA test and an LDH test (lactate-deshydrogenase) by an enzymatic reaction.
Results (in % relative to the sample, the average of 3 tests, each done in duplicate):
Quantity
Quantity
Number of
of LDH
of PGE2
doses in % (w/v)
Keratinocytes
released
released*
Non-irradiated sample
0.77 (million/well)
0
0
Irradiated sample, (UVB)
0.32
100
100
Medium + 114-1 at 0.005%
0.38
64
82
Medium + 114-1 at 0.010%
0.68
15
21
*= in % relative to the irradiated sample (= 100%) and non-irradiated sample (= 0%).
*=in % relative to the irradiated sample (=100%) and non-irradiated sample (=0%).
From the above results, it will be seen that the extract of baobab leaves analyzed and tested (product 114-1) has significant capacities as to:
capturing and neutralizing free radicals and reactive forms of oxygen (HO o and O{overscore ( 2 o +L )}), said product 114-1 acting at least in part by the capture of iron (“iron deprivation effect”);
reducing the quantity of lipoperoxidation induced by the UVA on human fibroblasts;
reducing the quantity of PGE2 and the cellular damage induced by UVB on human keratinocytes.
As to cosmetics, the sensory analysis permits detecting a substantial restructuring, softening and satinizing effect.
By way of non-limiting examples of practical embodiments of the invention, there will be described hereafter different cosmetic products or preparations comprising an extract of plants of the genus and Adansonia, particularly baobab.
EXAMPLE 1
A cosmetic product in the form of a hydro-protective gel for the face according to the invention could for example have a weight composition, constituted by fractions or phases A, B, C, D, E and F as follows, as indicated hereafter.
Fraction A:
Distilled water
49.950%
Elestab 50 J
0.500%
Carrageenan
0.100%
Fraction B:
Carbomer
0.300%
Distilled water
31.955%
Fraction C:
Propylene glycol
2.000%
Dimethicone copolyol
3.000%
Fraction D:
Triethanolamine, 20% in aqueous
2.145%
solution
Fraction E:
Kathon CG (Rohm and Haas)
0.050%
Fraction F:
Total dehydrated aqueous extract
0.500%
of leaves of Adansonia digitata
(type 1 extract)
Distilled water
9.500%
The process of preparation and production of the mentioned gel consists essentially in preparing separately the fractions A and B at 75° C. with turbine agitation, then cooling them to ambient temperature, preparing fraction F by dispersion of the dehydrated extract in 20 times its weight of water, adding to the fraction A successively the fractions B, C, D, E and F at ambient temperature and with turbine agitation and finally carrying out planetary agitation to homogenize.
EXAMPLE 2
A cosmetic product in the form of a hydrating cream for sensitive skins, which will be non-polluting, according to the invention could, for example, have a weight composition, constituted by fractions or phases A, B and C as follows, as indicated hereafter.
Fraction A:
Tegin
10.00%
Novata AB
1.00%
Miglyol 812
8.00%
Cetiol
5.00%
Eutanol G
2.00%
Fraction B:
Elestab 4112
0.35%
Distilled water
60.65%
Glycerine
3.00%
Fraction C:
Dehydrated mucilaginous extract
1.00%
of Adansonia digitata (type 1
extract)
Distilled water
9.00%
The process of preparation and production of the mentioned cream consists essentially in preparing separately the fractions A and B at 75° C., preparing the fraction C by dispersion with turbine agitation, pouring fraction A at 75° C. into fraction B at 75° C. with turbine agitation, cooling the obtained mixture, with planetary agitation, to 50° C., and introducing fraction C.
EXAMPLE 3
A cosmetic product in the form of anti-wrinkle cream, anti-free radical cream, protective of collagen elastin and fundamental substance, anti-skin aging and that improves micro-circulation, according to the invention, could for example have a weight composition, constituted from fractions or phases A, B and C as follows, as indicated hereafter.
Fraction A:
Cutina CBS
12.00%
Cutina E24
2.00%
Eumulgin B2
1.00%
Eutanol G
3.00%
Cetiol SB45
3.00%
Cetiol SN
4.00%
Fraction B:
Glycerine
5.00%
Distilled water
47.50%
Elestab 388
2.50%
Vegeseryl HGP
10.00%
Fraction C:
Dehydrated flavonoidal extract
2.00%
of Adansonia digitata (type 3
extract)
Distilled water
8.00
The process of preparation and production of the mentioned cream consists essentially in preparing separately the fractions A and B at 75° C., preparing fraction C by dispersion of the dry extract in four times its weight of water, pouring fraction A into fraction B with turbine agitation, cooling the mixture obtained, adding the fraction C at 50° C. and finally carrying out a single planetary agitation to ambient temperature.
EXAMPLE 4
A cosmetic product in the form of a capillary lotion to be vaporized and that is photoprotective, according to the invention could for example have a weight composition as indicated hereafter.
Ethanol
53.80%
Triethanolarnine
0.10%
Gantrez ES425
3.60%
Glycerine
1.00%
Flavonoid extract of leaves
1.00%
of Adansonia digitata (type 3
extract)
Panthenol
0.50
Propane/Butane
40.00%
The process of preparation and production of the mentioned capillary lotion consists essentially in mixing together the mentioned constituents, filtering the mixture obtained and packaging it with a propellant.
EXAMPLE 5
A cosmetic product in the form of soothing, repairing, hydrating, anti-edema, healing and radioprotective milk according to the invention could for example have a weight composition, constituted from fractions or phases A, B, C and D as follows, as indicated hereafter.
Fraction A:
Miglyol 812
8.00%
Jojobah Oi1
2.00%
Acetulan
3.00%
Sphingoceryl VEG
1.50%
Paraffin Oil
5.00%
Brij 76
4.00%
Fraction B:
Carbomer
0.50%
Elestab 4112
0.40%
Sorbitol
2.00%
Uvinul MS40
0.05%
Glucam E20
3.00%
Distilled water
58.05%
Fraction C:
Triethanolamine in 20% aqueous
solution
2.50%
Fraction D:
Completely Dehydrated extract of
5.00%
leaves of Adansonia digitata
(extract type 1 + extract type 3)
Distilled water
5.00%
The process of preparation and production of the mentioned after-sun milk consists essentially in preparing separately the fractions A and B at 75° C., pouring fraction A into fraction B with turbine agitation, adding fraction C, cooling, adding fraction D previously homogenized at 50° C. and cooling the obtained mixture with planetary agitation.
Of course, the invention is not limited to the described embodiment. Modifications remain possible, particularly as to the constitution of the various elements or by substitution of technical equivalents, without thereby departing from the scope of protection of the invention.
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A method and product effecting, in the skin, hair, eyelashes or nails of a human, an effect which can be emollient, softening, insulating, repair, hydration, soothing, emulsifying, nutrient, regenerative, anti-free radical, local anti-inflammatory, protective, photoprotective against UVB and UVA, anti-pollutant, anti-toxic, anti-sensitizing or inhibition of enzymes. There is applied to the skin, hair, nails or eyelashes of a human in need thereof, an effective amount of at least one material removed from the leaves of a plant of the genus Adansonia belonging to the family of Bombacaceaes by steeping in a liquid solvent and then removing the liquid to leave a dry material, the amount being effective to produce that effect. The plant is preferably Adansonia digitata or baobab.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method of manufacturing a friction speed change gearing of a type which comprises a housing, first and second rotary shafts rotably supported in said housing in axial alignment with each other, an inner race supported by said first rotary shaft, an outer race supported by said housing to be co-axial with said inner race, a plurality of cylindrical rollers mounted between said inner and outer races subject to an elastic deformation, and a spider member supported by said second rotary shaft to engage said rollers in a manner to allow them to freely rotate around their own axes and to drive or to be driven by said rollers when they make a planetary movement.
2. Description of the Prior Art
In the aforementioned friction speed change gearings, when said first rotary shaft is rotated by an outer driving power, the driving torque is transmitted to said second rotary shaft in a speed changing manner (in a speed reducing manner in this case) by way of said plurality of cylindrical rollers which make a planetary movement in an annular space defined by said outer and inner races and said spider member engaging said rollers.
In manufacturing a friction speed change gearing of this type, when said rollers are mounted in said annular space, they must be somewhat deformed or compressed in a diametrical direction. However, it is difficult to insert the relatively small cylindrical rollers into said annular space while compressing them in a diametrical direction and there is a danger that the rollers are damaged or distorted during such an inserting process thereby causing a problem that the friction speed change gearing does not provide an expected performance in operation.
In dealing with this problem, it has been proposed in Japanese Patent Application No. 53901/71 filed by the same assignee as that of the present application to manufacture a friction speed change gearing of this type by first forming a pre-assembly of said first rotary shaft, inner race, rollers, outer race, spider member, and second rotary shaft and secondly pressing the pre-assembly into a bore of the housing, wherein said bore is formed to have an inner diameter which is a little smaller than the outside diameter of said outer race so that said outer race is contracted when it has been pressed in said housing bore, thereby applying an elastic pre-stressing to said rollers, or by first preparing a pre-assembly of said first rotary shaft, etc., inserting said pre-assembly into a bore of the housing having an inner diameter which is larger than the outer diameter of said outer race and finally pressing an annular wedging member into an annular space left between said housing bore and said outer race, thereby contracting said outer race so as to apply an elastical prestressing to said rollers.
SUMMARY OF THE INVENTION
By contrast to the abovementioned former proposition which depends upon the concept of mechanically applying a contraction force to the outer race when mounting an assembly of the inner race, outer race and a plurality of cylindrical rollers mounted therebetween into the housing, the present invention proposes to apply an elastic pre-stressing to said plurality of rollers by thermally deforming the members concerned before assembly. In more detail, the present invention proposes a method of manufacturing a friction speed change gearing of the abovementioned type which comprises the steps of forming a provisional assembly of said first rotary shaft, inner race, rollers, spider member and second rotary shaft, forming a second assembly of said housing and outer race, heating said second assembly up to a temperature at which the inner diameter of said outer race which is normally smaller than that of the circumcircle of said rollers becomes larger than that of said circumcircle, inserting said provisional assembly into said second assembly and thus uniformly compressing said rollers due to a contraction of said housing and said outer race when they are returned to a normal temperature or a similar method which comprises the steps of forming similar provisional and second assemblies, cooling said provisional assembly down to a low temperature at which the diameter of the circumcircle of said rollers which is normally larger than the inner diameter of said outer race becomes smaller than said inner diameter, inserting said provisional assembly into said second assembly, and uniformly compressing said rollers due to expansion of said provisional assembly when it has been returned to a normal temperature.
BRIEF DESCRIPTION OF THE DRAWING
In the accompanying drawing,
FIG. 1. is a longitudinal sectional view of a friction speed change gearing for which the manufacturing method of the present invention can be applied;
FIG. 2. is a simplified transverse sectional view along line II--II in FIG. 1; and
FIGS. 3 and 4 are diagramatical longitudinal and transverse sectional views showing essential parts of a friction speed change gearing, illustrating the manufacturing method of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the following the invention will be described in more detail with reference to the accompanying drawings.
Referring to FIGS. 1 and 2 showing an example of the friction speed change gearing to which the method of the present invention is applicable, 1 designates a housing of the friction speed change gearing which, in the shown structure, is composed of several parts for the convenience of production and assembly. A first rotary shaft 2 and a second rotary shaft 3 are mounted in the housing 1 as rotatably supported by bearing means 4 and 5, respectively, in axial alignment with each other. In the following, only for the purpose of explanation, the shaft 2 is called the "input" shaft while the shaft 3 is called the "output" shaft, although they may be operated in a reversed manner so that the shaft 3 is an input shaft while the shaft 2 is an output shaft. In this connection, in the former case the friction speed change gearing naturally operates as a speed reduction gearing, whereas in the latter case the gearing operates as a speed multiplying gearing. The inner end of the input shaft 2 is formed as a reduced portion 2a which is rotatably received in a bearing bore 3a formed in the inner end portion of the output shaft 3 by way of needle elements 6, whereby the input and output shafts 2 and 3 are rotatably connected with or supported by each other at their inner ends and individually rotate around a common axis. An inner race 7 is mounted on the input shaft 2 and, in co-axial relation to the inner race, an outer race 8 is supported by the housing 1. Between the inner race 7 and the outer race 8 are mounted a plurality of cylindrical rollers 9 subject to an elastic deformation in diametrical directions so that the rollers present a somewhat elliptical configuration as shown in FIG. 2 in an exaggerated manner. A spider member 10 supported by the output shaft 3 is provided so as to engage said rollers in a manner to allow them to freely rotate around their own axes and to be driven by said rollers when they make a planetary movement around the annular space formed between the inner race 7 and the outer race 8. In the shown example of the friction speed change gearing the spider member 10 has arcuate bearing surfaces 11 adapted to engage the outer surfaces of the rollers 9 in a manner to maintain an oil film between the contacting surfaces when the rollers rotate relative to the bearing surfaces during their planetary movement. Although there are known various types of gearings which belong to the friction speed change gearing of the present category, the gearing of the structure as shown in FIG. 1 and 2 has an advantage in that the rollers are of a lighter weight thereby reducing the centifugal force generated therein, are better cooled in operation and are more relieved from various problems such as deformation, friction wearing, burn sticking, etc.
Now the method of the present invention for manufacturing or assembling the friction speed change gearings will be explained with reference to FIGS. 3 and 4.
First, the input shaft 2, inner race 7, rollers 9, spider member 10 and output shaft 3 which have individually been finished to predetermined dimensions are provisionally assembled as shown in FIG. 3 by employing a cylinder member 12 having inner and outer diameters as explained hereinunder. (In FIG. 3, however, the spider member and the output shaft are omitted for the sake of clarity in illustration.) On the other hand, another assembly of the housing 1 and the outer race 8 is prepared by mounting the latter in the former and providing a proper detent means between the two members. The assembly of the housing and the outer race is then soaked in a bath of hot oil and heated up to a predetermined temperature as explained hereinunder. When the assembly of the housing and the outer race has been heated up to the predetermined temperature, it is taken out of the oil bath and the first mentioned provisional assembly of the input shaft, inner race, rollers, spider member and output shaft is inserted into the assembly of the housing and outer race in a manner as explained hereinunder. As shown in FIG. 3, the cylinder member 12 of the provisional assembly is moved along the bore of the housing 1 which receives the outer race 8 until one end of the cylinder member abuts against one end of the outer race, and then the provisional assembly of the input shaft, inner race, rollers, spider member and output shaft is further moved into the outer race 8 until they come to a correct axial position with respect to the outer race and the housing while leaving the cylinder member 12 in the axial abutment with the outer race. Then the cylinder member 12 is removed and the housing 1 and the outer race 8 are cooled down to normal termperature. When the housing and the outer race are returned to normal temperature, they naturally contract and exert a diametrical compression on the rollers 10 which are then elastically pre-stressed in their assembled condition.
The dimensional conditions for the present method will now be explained. Designating the outer diameter of the cylinder rollers by D r , the diameter of the circumcircle of the plurality of cylindrical rollers 9 by D R , the outside diameter of the cylinder member 12 for the provisional assembly by D J , the inner diameters of the outer race 8 before and after its thermal expansion by D o and D o ', the inner diameters of the housing 1 before and after its thermal expansion by D h and D h' ' and the difference between the inner diameter of the cylinder member 12 and the diameter D R of the circumcircle of the plurality of rollers 9 by 2δ, the following relation is presumed to be satisfied:
D.sub.h > D.sub.J > D'.sub.O > D.sub.R + 2δ > D.sub.R > D.sub.O
in this case the thermal shrinkage 2ε is expressed by the following equation:
2ε = D.sub.R - D.sub.O
herein ε corresponds to the elastic deformation effected for one roller 9.
Now, by designating the maximum contacting stress (surface pressure) to be effected between the cylindrical rollers and the outer race 8 for accomplishing normal friction driving of the gearing by σ max, the thickness of the cylindrical rollers 9 by h, the elastic deformation ε of the cylindrical rollers 9 is given by the following formula: ##EQU1## Herein Er and Eo are the modulus of elasticity of the cylindrical rollers 9 and the outer race 8.
By expressing the temperature difference for the thermal shrinkage by ΔT and the thermal expansion coefficient of the outer race 8 by k and assuming that the thermal expansion of the outer race is very small when compared with its inner diameter D o , the following equation is generally established: ##EQU2## Since the conditon to be satisfied when the aforementioned provisional assembly of the input shaft, etc., is inserted into the heated up assembly of the housing and outer race is:
D.sub.O ' - D.sub.R > 0
the following conditions are obtained to be satisfied for performing the method of the present invention: ##EQU3## Therefore, when the dimensions h, D r and the material of the cylindrical rollers 9, the inner diameter D o and the material of the outer race 8 and the contacting pressure σ max required for the cylindrical rollers 9 to accomplish the friction driving are determined, the minimum temperature for the thermal shrinkage is obtained from Formula (1).
The method of the present invention to be performed depending upon the above engaging relations can also be performed by maintaining the assembly of the housing 1 and outer race 8 at normal temperature while soaking the provisional assembly of the input shaft 2, inner race 7, rollers 9, spider member 10, output shaft 3 and cylinder member 12 in a bath of a cold medium to cool them down to a predetermined low temperature.
From the foregoing it will be appreciated that the present invention requires a simple cylinder member 12 for the provisional assembly and a bath of hot oil or a low temperature liquid and that, in spite of this simple provision, the assembling process of the friction speed change gearing is made substantially easier when compared with the conventional process which depends upon the concept of mechanically applying pre-stressing to the friction rollers.
Although the invention has been explained with reference to particular embodiments thereof, it will be understood by those skilled in the art that various modifications can be made with respect to these embodiments without departing from the spirit of the invention.
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A method of manufacturing a friction speed change gearing of the type which comprises a housing, inner and outer races, a plurality of cylindrical planetary rollers mounted between the inner and outer races subject to elastic deformation, and a spider member engaging the planetary rollers, wherein the method is characterized by forming a first assembly including the inner race and the planetary rollers and a second assembly including the housing and the outer race, forming a temperature differential between the two assemblies, inserting the first assembly into the outer race in the second assembly and removing the temperature differentiation so that the rollers are uniformly compressed due to a thermal deformation which occurs when the temperature differentiation has been removed.
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CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
The present application is a continuation of U.S. application Ser. No. 12/619,760, filed Nov. 17, 2009, which is incorporated herein by reference in its entirety.
BACKGROUND
The present invention relates to plumbing fixtures such as toilets. In particular, the present invention relates to the flush assembly and flush sequencing for toilets.
Conventional toilets utilize a single mechanical flush sequence to evacuate waste from the toilet bowl, rinse the bowl, and possibly to refill a water tank. Simple mechanical components such as gravity operated flapper valves and float controlled fill valves are normally used to control the passage of water through the bowl and the filling of the tank. The trade-off for such a simple mechanical flush assembly is wasted water consumption in low waste conditions and inadequate or inconsistent rinsing of the bowl in high waste conditions.
Over time there have been numerous revisions and improvements made to the conventional toilet. For example, several toilets have been devised with electronically controllable flush, rinse and fill components, see e.g., U.S. Pat. Nos. 5,548,850 and 6,332,229. These patents also disclose toilets with alternate flush sequences. And, more forceful rinsing action has been achieved using jet components, such as disclosed by U.S. Pat. No. 2,715,228. However, as of yet the flush control components and sequencing of conventional toilets has often been insufficient to achieve an efficient and adequate flush in varied waste load conditions.
There is thus a need for toilets with advanced flush assemblies and sequencing to better address problems with known toilets.
SUMMARY
In one aspect the invention provides a toilet having a bowl with a bowl outlet and a rim having a rim outlet. A flush valve operates to control flow through the bowl outlet. A rim supply valve operates to control flow into the bowl rim. The toilet flushes water through the bowl during a flush sequence in which the rim supply valve and the flush valve are both opened and closed twice, first during a pre-rinse cycle and subsequently during a rinse cycle. The rim supply valve and the flush valve are closed at the beginning and end of the cycles and open therebetween.
In another aspect the invention provides a toilet as described that is selectively operable in first and second flush sequences. The first flush sequence includes a pre-rinse cycle in which the toilet flushes water through the bowl by opening and closing the rim supply valve and the flush valve once. The second flush sequence includes the pre-rinse cycle and a rinse cycle in which the rim supply valve and the flush valve are both opened and closed twice, first during the pre-rinse cycle and subsequently during the rinse cycle.
In still another aspect the invention provides a flush sequence for a toilet which includes initiating a pre-rinse cycle and subsequently initiating a rinse cycle for the same flush event. The pre-rinse cycle includes opening the supply valve to flow water to the rim and pass water through the rim outlet into the bowl, opening the flush valve to empty the bowl through the bowl outlet, and closing the flush valve. The rinse cycle includes opening the supply valve to flow water to the rim and pass water through the rim outlet to the bowl, opening the flush valve to evacuate the bowl through the bowl outlet, and closing the flush valve and the supply valve.
To improve flush performance, the flush sequence, particularly the rinse cycle, can further include using an eductor to increase the flow rate of rinse water into the bowl.
Additionally, the toilet can include an electronic control which controls the open and close operation of the flush valve and the rim supply valve. In addition to the rim water supply, the electronic control can control filling and output flow from a reservoir water supply, such as toilet tank. And, level sensors, such as mounted in the bowl and/or the water supply reservoir, can be coupled to the electronic control for sending bowl and reservoir level input signals to the electronic control, and thereby control fill levels in both.
Hence, the invention provides an advanced electronically controlled toilet which provides an improved flush. To save water in low-waste conditions, the toilet can be operated in a quick or short flush mode, in which the bowl is briefly rinsed by water from the bowl rim. For higher waste conditions, the user can select a long or dual rinse mode in which the bowl is pre-rinsed with water from the rim to empty the waste and then rinsed again, this time with rim water which may be eductor-assisted. To do this, the electronic control opens and closes the rim supply valve and the bowl flush valve one time during the pre-rinse cycle and a second time during the regular rinse cycle. Thus, fully opening and closing these valves twice during a single flush event. Additional electronic control and sensing can be provided to further automate and regulate the flushing operation.
The foregoing and still other advantages of the invention will appear from the following description. In that description reference is made to the accompanying drawings which form a part hereof and in which there is shown by way of illustration a preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a toilet according to the present invention with its lid down;
FIG. 2 is a perspective view of the toilet of FIG. 1 with its lid up;
FIG. 3 is a side view of the toilet with the bowl, the trapway, and the plumbing components shown in phantom lines;
FIG. 4 is a cross-sectional side view of the toilet taken along line 4 - 4 of FIG. 1 ;
FIG. 5 is a cross-sectional side view of the toilet taken along line 5 - 5 of FIG. 1 ;
FIG. 6 is a front lower left side view of some of the internal plumbing components of the toilet of FIG. 1 ;
FIG. 7 is a simplified schematic of the plumbing of the toilet of FIG. 1 ;
FIG. 8 is a process chart of a long flush sequence for the toilet of FIG. 1 ; and
FIG. 9 is a process chart of a short flush sequence for the toilet of FIG. 1 .
DETAILED DESCRIPTION
Referring now to FIGS. 1-5 , a toilet 10 is shown that is configured to have two flushing sequences. Although the specifics of the flushing sequences will be described in more detail below, an overview of the components of the toilet 10 and their connectivity will be described first to provide a structural context for the flushing sequences. Although a two-part modular construction is shown, it should be appreciated that the toilet 10 need not be of a modular design and could be of a more conventional toilet assembly. Accordingly, the modular assembly is only one example of a toilet that may utilize the flushing sequences described below.
As best seen in FIGS. 1 and 2 , the toilet 10 includes a frontal basin portion 12 and a rear backpack portion 14 . In the embodiment shown, the toilet 10 is designed to be a modular assembly in which, generally speaking, the rear backpack portion 14 supports and/or houses many of the functional components of the toilet 10 while the frontal basin portion 12 is one of several possible front-side attachments which is adapted to be connected to the rear backpack portion 14 . As different front-side attachments may be made, the toilet 10 can take on various appearances using a single rear backpack portion 14 . Moreover, the rear backpack portion 14 may be configurable to receive various components that provide accessory functions to the toilet such as a bidet wand, automatic seat and/or lid lifting mechanisms, air circulating functions, music accessories, and so forth.
The frontal basin portion 12 includes a bowl 16 extending from a bowl rim 18 at the top of the bowl 16 to a bowl opening 20 proximate the bottom of the bowl 16 . The bowl rim 18 includes a channel 22 (best seen in FIG. 4 ) which selectively receives water which may then be directed into the bowl 16 during a flushing sequence via apertures or rim openings in an underside of the bowl rim 18 . The bowl opening 20 may be placed in selective communication with a trapway 24 by a flush valve 26 that is located therebetween.
The flush valve 26 is electromechanically controlled by a control board 28 (e.g., a controller or electrical control, and as schematically illustrated in FIG. 7 ) which is located in the rear backpack portion 14 of the toilet 10 . This control board 28 is electronically coupled to a motor 30 which is mechanically coupled to the flush valve 26 via a linkage 32 such as a belt or a chain. When the motor 30 drives the linkage 32 , the flush valve 26 may be actuated from an open position to a closed position or vise-versa. In the closed position, shown in FIGS. 3 and 4 , an arcuate surface 34 of the flush valve 26 forms a seal about the bowl opening 20 at the bottom of the bowl 16 such that any water and waste contents located in the bowl 16 are substantially retained in the bowl 16 . Then, in the open position (not shown), the flush valve 26 is rotatably actuated from the close position to remove the seal between the bowl 16 and the trapway 24 such that the contents of the bowl 16 can pass from the bowl 16 into the trapway 24 such as during a flushing operation. Although a flush valve 26 that is rotatable is shown, other types of valves could also be used to selectively place the bowl 16 in fluid communication with the trapway 24 .
The trapway 24 is a tube-like passage that snakes under the bowl 16 and rearwards in a sideways S-shape from the bowl opening 20 to a trapway end 36 which connects to an opening in the floor which connects to a waste line pipe (not shown) or the like. The geometry of the trapway 24 is such that a first leg 38 of the trapway 24 proximate the flush valve 26 extends downward to a dip 40 , a second leg 42 of the trapway 24 extends upward from the dip 40 to a weir 44 , and a third leg 46 of the trapway 24 extends downward from the weir 44 to connect to the opening in the floor. To prevent the escape of trapped sewer gases from the waste water line into the bowl 16 (and into the atmosphere surrounding the toilet 10 ), water may be captured in the space between the dip 40 and the weir 44 to form a water seal in the trapway 24 .
A water level sensor 48 (schematically illustrated in FIG. 7 ) may also be coupled to the bowl 16 to detect a level of the water in the bowl 16 . The water level sensor 48 may be electronically coupled to the control board 28 to indicate the current state of water in the bowl 16 (e.g., a water level of the bowl 16 ) via a signal. The water level sensor 48 may be utilized to detect the water level in the bowl 16 and to stop the feeding of water to the bowl 16 during a flush sequence during a fill step or in the event that a blockage in the trapway 24 or the like prevents water from emptying from the bowl 16 .
Now with additional reference to FIGS. 5 , 6 , and 7 , the rear backpack portion 14 supports and houses the plumbing utilized in performing the flushing sequences. Beginning at the source, a water supply 50 (illustrated schematically in FIG. 7 ) provides water to the other plumbing components. The water supply 50 is connected with the toilet 10 via an inlet line 52 that comes in from the behind the rear backpack portion 14 of the toilet 10 . The inlet line 52 is connected to a solenoid valve 54 . The solenoid valve 54 may be electronically controlled by the control board 28 , to selectively place the inlet line 52 in fluid communication with a tank 56 via a tank fill line 58 (i.e., a filler) or the bowl rim 18 via a rim line 60 . The rim line 60 is placed in fluid communication with the bowl rim 18 via a spud connection or the like at an end 68 of the rim line 60 . Although a single solenoid valve 54 is shown in FIGS. 3 to 6 , a separate rim supply valve 54 a and fill valve 54 b may also be used as illustrated in the schematic of FIG. 7 .
Notably, the tank 56 (or water supply reservoir) is also placed in communication with the rim line 60 via an eductor line 62 which connects to the rim line 60 to form an eductor 64 . This eductor 64 may assist in providing a particularly strong flow of water to the rim 18 when water from the tank 56 supplements the water being supplied via the rim line 60 .
Additionally, a float switch 66 may be located in the tank 56 . When the water level in the tank 56 exceeds a pre-determined threshold level, typically causing a portion of the float switch 66 to rise within the tank 56 , this displacement of a portion of the float switch 66 may cause the closing of a shutoff valve (possibly either by a direct mechanical connection between the float switch 66 and the shutoff valve or by a sending an electrical signal to the control board 28 which operates the shutoff valve) which temporarily closes off the water supply 50 from the other plumbing components.
With reference to FIG. 7 , a summary of the connectivity of the control board 28 to the various components may be made. With respect to the bowl 16 , the control board 28 may be electrically coupled to the water level sensor 48 and the motor 30 that controls the open or closed state of flush valve 26 . With respect to the plumbing components in the rear backpack portion 14 , the control board 28 is electrically coupled to the solenoid valve 54 (illustrated in FIG. 7 as separate rim supply valve 54 a and fill valve 54 b ) which controls the flow of water from the water supply 50 into the tank 56 and into the rim 18 . Further, the control board 28 may receive a status of the state of the water level in the tank 56 via the float switch 66 . Although not previously described, the control board 28 is also electronically coupled to a short flush button 70 and a long flush button 72 . Of course, rather than being buttons, these could be any of a number of types of controls, switches, buttons, or the like. The short flush button 70 and the long flush button 72 may be used to start a short flushing sequence or a long flushing sequence that will now be described.
Referring now to FIG. 8 , a long flush sequence 800 is shown. The long flush sequence 800 is initiated when the long flush button 72 is pressed according to step 802 . Once the control board 28 detects the operation of the long flush button 72 , the control board 28 instructs the various components to perform a pre-rinse, rinse, and fill of the bowl 16 .
The pre-rinse cycle begins with the control board 28 instructing the rim supply valve 54 a to open and then close according to step 804 to pre-rinse the bowl 16 . This pre-rinse cycle may remove debris, such as toilet paper, stuck on the walls of the bowl 16 above the water fill line. Only a small of amount of water may be used to perform the pre-rinse of the bowl 16 .
Next, according to step 806 , the flush valve 26 is opened to remove waste from the bowl 16 while the rim supply valve 54 a remains closed. This is a short, water efficient step, which removes the waste from the bowl 16 . The flush valve 26 is then closed to seal the bowl opening 20 of the bowl 16 according to step 808 .
Once the pre-rinse cycle is completed, the rinse cycle begins. After the flush valve 26 closed, the rim supply valve 54 a is opened according to step 810 to start the bowl rinse cycle. After a sufficient amount of water has been introduced into the bowl 16 , the flush valve 26 is opened according to step 812 to evacuate the water accumulated during the rinse cycle from the bowl 16 . While the flush valve 26 is opened, water may continued to be supplied to the rim 18 to rinse the bowl 16 . After a period of time, the flush valve 26 is closed according to step 814 to seal the bowl 16 and the rim supply valve 54 a is closed according to step 816 to end the bowl rinse cycle.
Notably, while the rim supply valve 54 a is opened and supplying water to the rim 18 via the rim line 60 either during the pre-rinse cycle or the rinse cycle, the eductor 64 may be used to increase the rate at which water is supplied to the rim 18 . As the water introduced from the tank 56 to the rim line 60 via the eductor line 62 increases the flow rate of the rinse water into the bowl rim 18 , the water is supplied more quickly and in such a manner as to more effectively and efficiently rinse the bowl 16 . At greater flow rates, better bowl rinsing can be performed more quickly and with less water than with eductor-less flush mechanisms.
After the bowl rinse cycle is complete, then the fill cycle begins to refill the bowl 16 for another use of the toilet 10 . During the fill cycle, the fill valve 54 b is open and then closed according to step 818 to supply water to the water tank 56 (which may have been partially or fully depleted during the pre-rinse and rinse cycles) and to re-fill the bowl 16 . The fill valve 54 b remains open until the bowl 16 and the tank 56 are refilled. The determination of the levels of water in the bowl 16 and tank 56 may be determined by the water level sensor 48 and the float switch 66 , respectively. Of course, a stop condition for refilling the bowl could potentially be based on one of or both of the water level sensor 48 and the float switch 66 or could be based on some other sensor or timing mechanism.
It should be appreciated that during the fill cycle, the rim supply valve 54 a may be closed and, accordingly, the rate of flow of water into the bowl 16 may be comparatively slower than during the pre-rinse and/or rinse cycle. Of course, depending the particular plumbing configuration, the bowl re-fill may be accomplished using an additional bowl fill valve or by using the rim supply valve 54 a either alone or in combination with the fill valve 54 b.
Referring now to FIG. 9 , a short flush sequence 900 is illustrated which may be generally used for the elimination of light or low waste, such as urine or perhaps small amounts of bath tissue, from the bowl 16 . Upon pressing the short flush button 70 according to step 902 , the short flush sequence 900 is initiated. First, a pre-rinse cycle occurs in which the rim supply valve 54 a is open and then closed according to step 904 to supply a shot of water to the rim 18 and clear any waste or debris from the walls of the bowl 16 . Next, the flush valve 26 is opened to remove the water and waste from the bowl 16 via the trapway 24 according to step 906 . After the water and waste are eliminated from the bowl 16 , the flush valve 26 is closed according to step 908 . The fill valve 54 b is then open and closed to re-fill the water in the bowl 16 and the tank 56 according to step 910 . Of course, as described above, the re-fill step may be achieved by opening the fill valve 54 b or by opening one or more other valves to fill the tank 56 and bowl 16 .
Thus, a toilet is disclosed that is capable of performing two flush sequences. The longer of the two flush sequences is engineered with the removal of solid waste or the like from the bowl. The shorter of the two flush sequences is engineered with the removal of light waste or the like from the bowl. Given the benefits of water conservation, these flush sequences aim to use an appropriate amount of water for the task at hand.
Further, these flush sequences may utilize a pre-rinse cycle which helps to more efficiently use the water of the flushing sequence. In contrast to conventional flush cycles, which may have water continuously fed to the bowl via the rim while water continually drains from the bowl opening, the rim supply valve 54 a may be opened and closed to provide an initial shot of water to pre-rinse the walls and then opened again after the bowl has been evacuated. By shutting off the rim supply valve in between the pre-rinse cycle and the subsequent rinse cycle, the amount of water used over the flush cycle is reduced.
While a specific embodiment of the present invention has been shown, various modifications falling within the breadth and scope of the invention will be apparent to one skilled in the art. For example, one or more jets may assist in vacating water and waste from the bowl. Thus, the following claims should be looked to in order to understand the full scope of the invention.
INDUSTRIAL APPLICABILITY
Disclosed is a plumbing fixture, such as a toilet having an advanced flush control assembly and sequencing providing efficient water consumption with adequate rinsing of the bowl.
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A toilet has an electronic flush assembly operable in either a short or long flush sequence selectable by a user. The long flush sequence includes a pre-rinse cycle and a rinse cycle in which the a supply valve and a flush valve are both opened and closed twice, once each first during the pre-rinse cycle and again during a subsequent rinse cycle. The rim supply valve and the flush valve are opened during the pre-rinse and rinse cycles but are closed at the start and end of each cycle. An electronic control controls operation of the valves as well as water supply control components. Level sensors can also be included to provide feedback to the controller, for example, to prevent overflow conditions.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of Invention
[0002] The present invention relates to intercoms and, more specifically, to a wirefree intercom having improved transmission quality.
[0003] 2. Description of Prior Art
[0004] Conventional intercoms are powered by the wall outlet and transmit the voice of the speaker over the wires installed throughout the home. These intercoms use power line modulation techniques and have limited ranges due to the need for physical attachment to the power lines in the wall, as well as when the possibility of phase changes in the power connection that may interfere with the signal. In addition, the sound quality is often limited in such systems, and when there is a motor (such a hair dryer or vacuum cleaner) also in operation on the circuit, the signal is often distorted or destroyed.
[0005] Wireless intercoms use a radio signal and, like conventional intercoms, are powered by a wall outlet. These devices usually employ Family Radio Service (FRS) radio technology and have decent range capabilities. However, such devices do not provide security when multiple devices are employed in a dwelling. For example, if there are five units in a home and all are set to the same security number, each unit allows for reception of a conversation occurring between any other two units. In a business environment, this loss of security is not desirable. Additionally, such devices consume too much power and are thus not feasibly implemented without a direct power connection to a wall outlet. Some wireless intercoms use both wall power and batteries. In addition to limitation described above with respect to wireless intercoms, the batteries in such systems will only last about a day or two when the device is left on.
SUMMARY OF THE INVENTION
[0006] It is a principal object and advantage of the present invention to provide a wirefree intercom system that avoids the need for line power.
[0007] It is another object and advantage of the present invention to provide a wirefree intercom system that has low power consumption.
[0008] It is an additional object and advantage of the present invention to provide a wirefree intercom system having an unlimited number of units.
[0009] It is a further object and advantage of the present invention to provide a wirefree intercom system that provides secure conversation.
[0010] It is another object and advantage of the present invention to provide a wirefree intercom that is not affected by line noise.
[0011] It is an additional object and advantage of the present invention to provide a wirefree intercom system that has a long range.
[0012] It is a further object and advantage of the present invention to provide a wirefree intercom system that has clear sound qualities.
[0013] Other objects and advantages of the present invention will in part be obvious, and in part appear hereinafter.
[0014] In accordance with the foregoing objects and advantages, the present invention comprises wirefree intercom having circuitry and control processing that significantly reduces power consumption. More particularly, the intercom comprises a base unit and an antenna attached thereto for communicating with any number of other based units. Each base unit comprises a microcontroller, transceiver, codec, and speaker for receiving digital signal packets and converting into audible sounds and a microphone associated with the codec, microcontroller, and transceiver for converting sounds into digital data packets and transmitting to a remote intercom. The power reduction circuitry comprises the use of a wake timer and a talk timer that limit the amount of time that the associated circuitry remains operative. More particularly, the wake timer places the microcontroller in a timed, periodic sleep mode. After the expiration of the wake timer, the microcontroller activates the transceiver and checks for the presence of appropriate digital signals. If no signals are received, the intercom returns to sleep mode, thereby reducing power consumption. The intercom is programmed to receive digital transmission of data over a first channel and then corrects any errors in the digital data using a retransmission of the digital data over a second channel that is sufficiently spaced apart from the first channel to avoid the possibility of interference affecting both the first and second channels
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The present invention will be more fully understood and appreciated by reading the following Detailed Description in conjunction with the accompanying drawings, in which:
[0016] FIG. 1A is a perspective view of a wirefree intercom base unit according to the present invention.
[0017] FIG. 1B is a perspective view of a wirefree intercom base unit according to the present invention.
[0018] FIG. 2 is a schematic of circuitry for a wirefree intercom base unit according to the present invention.
[0019] FIG. 3 is a flowchart of a control process for a wirefree intercom base unit according to the present invention.
[0020] FIG. 4 is a continuation of the flowchart of FIG. 3 of a control process for a wirefree intercom base unit according to the present invention.
[0021] FIG. 5 is a flowchart of a pairing process for a wirefree intercom base unit according to the present invention.
[0022] FIG. 6 is a flowchart of a security process for a wirefree intercom base unit according to the present invention.
[0023] FIG. 7 is a flowchart of a power conservation process for a wirefree intercom base unit according to the present invention.
[0024] FIGS. 8A and 8B are schematics of interference in a dual channel system according to the present invention.
[0025] FIG. 9 is flowchart of a digital signal restoration process for a wirefree intercom base unit according to the present invention.
DETAILED DESCRIPTION
[0026] Referring now to the drawings, wherein like numerals refer to like parts throughout, there is seen in FIGS. 1A and 1B a wirefree intercom 10 according to the present invention. Intercom 10 comprises a base unit 12 and an antenna 14 attached thereto. Base unit 12 houses the circuitry for providing wireless intercom capabilities, without the need for line power or excessive battery power usage, as will be described hereinafter. Base unit 12 further houses a power source, such as a conventional battery 13 , which may be received in a compartment 15 formed into the bottom of base unit 12 . Base unit 12 may further include a channel select button 16 , which allows a user to cycle through the preselected channels or select all of the preselected channels for transmission and reception. Intercom 10 may further comprise any number of illuminating regions 17 , such as LEDs, for reflecting the current operating mode of base unit 12 , such as “sleep” or active, for indicating whether the power “on,” etc. Intercom 10 further comprises a talk button 18 for transmitting from intercom 10 , a microphone 20 for receiving sounds to be transmitted, and a volume button 21 to control the volume of sounds played back on intercom 10 .
[0027] Referring to FIG. 2 , base unit 12 comprises a microcontroller 22 interconnected to a codec 24 for converting analog signals to digital signals (and vice versa) and interconnected to a digital radio transceiver 26 for transmitting and receiving digital signals. Microcontroller 22 is selected to be able to perform radio base-band functions, carry out compression and de-compression of digitized data, assemble digital data transmission signals, and disassemble received digital data signals. As will be explained in detail hereinafter, microcontroller 22 further includes a wake timer 28 and a talk timer 30 for controlling whether and when base unit 12 is in “sleep” mode, thereby conserving energy, or a “wake” mode, where microcontroller 22 periodically “sniffs” for incoming signals. It should be recognized that wake timer 28 and talk timer 30 may be implemented in separate hardware devices or by programming wake timer 28 and a talk timer 30 into microcontroller 22 . Preferably, wake timer 28 of microcontroller 22 (and any other timers) comprises a watchdog style timer that may be operated while microcontroller 22 has otherwise been deactivated. Microcontroller 22 may comprise a low-power CMOS 8-bit microcontroller based on the AVR enhanced RISC architecture, such as an ATMEL Mega 88 available from the Atmel Corporation of San Jose, Calif.
[0028] Transceiver 26 is a conventional 915 MHz, multi-spectrum transceiver that is further associated with antenna 14 for transmitting and receiving digital radio signals. Transceiver 26 preferably supports about 125 radio channels, which may be chosen automatically or at the request of microcontroller 22 , and wherein each channel allows for communications without interfering with other channels. Transceiver 26 should be capable of reliably transmitting to and from another intercom 10 at distances of up to 1000 feet. Transceiver 26 may comprise a low power, low-IF transceiver designed for operation in the license-free ISM bands at 433 MHz, 868 MHz and 915 MHz, such as an ADF 7020 available from Analog Devices, Inc. of Norwood, Mass.
[0029] Codec 24 is a conventional encoder-decoder for converting analog signals to digital code, and vice versa. Codec 24 may further compress the signals to conserve bandwidth. Codec 24 may comprise an ultra low-power codec including a microphone supply, preamplifier, 16-bit ADC, 16-bit DAC, serial audio interface, as well as power management and clock management for the ADC and the DAC. The sampling frequency of the ADC and of the DAC is preferably adjustable 4 kHz to 48 kHz. For example, codec 24 may comprise an XE3005 available from Semtech Corporation of Camarillo, Calif.
[0030] The analog to digital input portion of codec 24 is interconnected to a microphone 32 for receiving voice signals and creating electrical analog voice signals from captured sounds. Codec 24 encodes the analog voice signals into digital packets and provides the encoded digital packets to microcontroller 22 . Microcontroller 22 buffers the digitized sound packets and applies compression algorithms, such as Adaptive Differential Pulse Code Modulation (ADPCM) or Delta Modulation, if desired, to reduce the packet size. An identification tag is also added to the packets, and they are sent by microcontroller to transceiver 26 for transmission to another base unit 12 .
[0031] The digital to analog portion of codec 24 is interconnected to a filter 34 for conditioning outgoing analog signals and reducing noise. Filter 34 may comprise an operational amplifier and conventional low pass, high pass, or band pass filter.
[0032] Filter 34 is further interconnected to an amplifier 36 for improving the quality of signals in the sound spectrum at the lowest possible power consumption. Microcontroller 22 may be interconnected directly to amplifier 38 for supplying control signals that control the power consumption of amplifier 38 . Amplifier 38 may comprise a conventional, off-the-shelf amplifier.
[0033] Amplifier 38 is connected to a speaker 40 for outputting audible sounds based on the amplified sound signals converted by codec 24 and processed by filter 36 .
[0034] Packets of data containing digitized voice signals, as well as an appropriate ID information data string, that are received by transceiver of base unit 12 are transferred from transceiver 26 to microcontroller 22 for playback. Microcontroller 22 decompresses the data (if necessary) and sends the signals to codec 24 . Codec 24 then converts the digital signals to analog sound signals, which are filtered by filter 34 , amplified by amplifier 36 , and output by speaker 38 .
[0035] The present invention reduces power consumption by engaging in a nearly complete shutdown of all circuitry for a predetermined period of time, which may be variable, depending on usage of intercom 10 . Referring to FIG. 3 , the basic power-saving “sniff” process 40 of the present invention commences with the setting 42 of wake timer 28 , thereby placing intercom 10 in sleep mode. As a result, power consumption for unit 12 is reduced to the microamp range. When wake timer 28 expires 44 , microcontroller 22 awakes from sleep mode 46 , and “sniffs” for a signal by activating transceiver 26 for the receipt of signals 48 . A check is then performed 50 to determine whether any information received by transceiver 26 is discernable. If so, the incoming ID byte is checked 52 against a reference database 54 to determine whether it matches a stored ID. If not, base unit 12 goes back to sleep at step 42 , thereby conserving energy. If the ID matches, then microcontroller 22 awakens codec 24 , and enters full function mode, as illustrated in FIG. 4 .
[0036] Referring to FIG. 4 , if an ID is matched at step 52 , playback of data is enabled 56 . More specifically, codec 24 is enabled thereby starting packet reception, packet decompression, and error correction. Talk timer 30 is started 58 , and a check is performed 60 to determine whether packet reception has finished. If not, control returns to step 56 . If packet reception has finished at step 60 , a check is performed to determine whether talk button 18 has been depressed 62 . If talk button 18 has not been depressed, talk timer 30 is checked 64 . If talk timer 30 has expired, wake timer 28 is set 66 and intercom 10 is sent into sleep mode 68 . If talk timer 30 has not expired, control returns to step 50 . If the talk button was depressed at step 62 , talk timer 30 is extended 70 and a command byte is sent out 72 by transceiver 26 (to another intercom 10 ) to reverse the direction of communication. Transmission of data by intercom 10 is then enabled 74 . More particularly, microcontroller 22 switches transceiver 26 from receive mode to send mode, sound is collected by microphone 32 , and the resulting analog signals are converted by codec 24 into packet data. Microcontroller 22 compresses the packets, if desired, adds the appropriate ID, and assembles the data stream for transmission by transceiver 26 to another intercom 10 .
[0037] Intercom 10 may further be provided with a “pair” button 76 for commencing a pairing process 78 by which two or more intercoms 10 are configured for transmission therebetween. Referring to FIG. 5 , pairing of a first intercom 10 with a second intercom 10 (or any number of additional intercoms 10 ) may be accomplished through pairing process 78 programmed into each intercom 10 . When a user wishes to pair two or more intercoms, the user presses 80 pair button 78 of first intercom 10 . The user then depresses 82 pair button 78 of any additional intercoms 10 . When pair button 78 is pressed, first intercom 10 checks internal memory 84 to determine whether an ID has been previously stored. If no ID has been previously stored 84 , receiver 26 of first intercom 10 listens for a predetermined period of time 86 , such as one second, and checks 88 to determine whether an ID has been received (from another intercom 10 ). If no ID is received from another intercom 10 at step 88 , first intercom generates a random ID 90 and begins transmitting the ID 92 for a predetermined amount of time. Intercom 10 may optionally decrease its RF output level by 30 dbm, so that the “teach” range is reduced to the immediate area. Intercom 10 then stored the ID 94 and sounds a successful pair 96 . If an ID has been sent by another intercom 10 and received at step 88 , first intercom 10 stores the ID in non-volatile memory 94 and generates a success tone from speaker 96 . After depressing pair button 76 of second intercom 10 at step 84 , second intercom cycles through the same process 78 as first intercom, and checks whether an ID is stored in memory 98 . If first intercom 10 has an ID stored in memory at step 84 and second intercom 10 does not, the ID of first intercom 10 is transmitted 100 to second intercom 10 , which will be listening for a predetermined time 102 . If first intercom 10 did not have an ID stored at step 84 , any stored ID in second intercom 10 will be transmitted to first intercom 10 and received at step 88 . If neither first nor second intercom 10 has an ID stored, the ID that is generated by first intercom 10 at step 90 and transmitted at step 92 will be received by second intercom 10 at step 102 , checked by second intercom 10 at step, stored in memory 106 , and a successful pair will be sounded 108 .
[0038] The present invention further provides for multiple, secure conversations occurring simultaneously on intercom 10 . As explained above, transceiver 26 supports multiple channels e.g., 125 channels. Preferably, a limited number, such as four, are dedicated for transmissions on intercom 10 , which may be indicated by a series of LEDS 110 on intercom 10 . Intercom 10 may further be configured to allow a user to select the specific channel to be used at all times, and may additionally be configured so that a user may choose to receive transmissions on “all channels” so that intercom 10 will receive and playback transmissions on any of the designated channels. Visual indication of the status may be reflected by cycling through four LEDs 110 as button 16 is depressed, to indicate transmissions on each of four particular channels for example, or lighting all LEDs when all channels have been selected. When a call is transmitted from an originating intercom 10 , the sound is played back on all intercoms 10 set to receive the designated channel (or set to receive “all channels”) and which have previously been “paired” to the originating intercom, i.e., the stored ID in all receiving intercoms 10 matches the ID of originating intercom 10 .
[0039] Referring to FIG. 6 , a security protocol process 112 for engaging in secure transmissions may begin when a transmission on a designated channel from a first intercom 10 is initially received 114 by a second intercom 10 (or any additional intercoms 10 ). The second intercom then checks 116 to determine whether it is set to playback the channel of the first intercom 10 . If not, playback is inhibited 118 . If the channel is confirmed at step 116 , first and second intercoms select one of the non-designated channels 120 of transceiver 26 . For example, first and second intercoms 10 may using the last three digits of the ID of first and second intercoms 10 to select one or more of the unused 125 channels. Selection of multiple channels allows first and second intercoms 10 to have a back-up channel in case of interference on the initially selected channel. Alternatively, first and second intercoms 10 may use other means to select an unused channel or channels, such as a random channel selection. Selection 120 concludes with first and second intercoms 10 exchanging the channel or channel set, and first and second intercoms 10 then move transmission to the selected channel or channels 122 . The transmission may then be played back 124 on second intercom 10 . A user of second intercom 10 may then depress talk button 18 to respond the initial transmission 126 . A timer may started 128 (and reset) each time the user of second intercom 10 depresses talk button 18 , and then checked for expiration 130 so that first and second intercoms are reset to the designated, non-secure channel or channels 132 , as soon as transmissions conclude. Security process 112 allow other intercoms 10 to freely communicate on the designated channels without interfering with communications ongoing between first and second intercoms 10 on the secure channel or channels. Security process 112 may be provided as a default setting, and first and second intercoms 10 may be provided with a bypass switch 134 that allows a user to bypass security process 112 and remain in non-secure mode so that any other “paired” intercom 10 may playback the conversation. As two or more communicating intercoms 10 also provide the IDs created during pairing process 78 when they communicate, it is also possible that multiple set of intercoms 10 , each set having a different ID, may communicate securely on a given channel with respect to any intercom 10 not programmed to playback communications including that ID even if set to receive signal on the given channel.
[0040] Referring to FIG. 7 , microcontroller 22 may implement a multi-stage, power-saving sleep mode process 136 , thereby substantially reducing power demand. In a first stage 138 , intercom 10 is actively engaged in a connection, i.e., all components are enabled, intercom 10 is connected to another intercom 10 , or intercom 10 is actively transmitting and receiving signals. A check is performed periodically 140 to verify that intercom 10 is active. If intercom 10 is inactive, intercom 10 is placed into a second, partial sleep stage where all unneeded components are disabled 142 . For example, amplifier 36 and LEDs 110 may be powered down to conserve energy. However, transceiver 26 is kept on to verify whether other intercoms have also terminated the connection. In addition, a sleep timer is started to measure a first sleep period 144 that controls how long intercom 10 is in stage two 142 . For example, sleep timer may be set for one hour. A check is then performed 146 to determine whether there is any system activity. If so, control returns to step 138 . If no activity is detected, the sleep timer is checked for expiration 148 . If the sleep timer has expired, intercom 10 enters a third sleep stage 150 where power is turned off to all components and wake timer 28 is set to measure a second time period 152 . Wake timer 28 is preferably set for 500 milliseconds. The sleep timer is also started 154 to measure a second sleep period. Power saving process 136 then follows the basic “sniff” process, as illustrated in FIG. 3 , every 500 milliseconds, i.e., a check is performed 156 to determine whether a signal of interest has been received. If no signal are detected at step 156 , sleep timer is checked 158 to determine whether intercom 10 has been in third stage 150 for more than a predetermined time, such as four hours. If so, intercom 10 enters a final sleep stage 160 , where all components are turned off and wake timer 28 is set 162 for a longer period of time that at step 152 , such as two seconds. As illustrated in FIG. 3 , microcontroller 22 executes the “sniff” process of FIG. 3 every two seconds, thereby further reducing power consumption while intercom 10 is in third stage 150 . It should be recognized that multi-stage, power-saving sleep mode process 136 may be implemented in any digital transmitting and receiving device having a transceiver and microcontroller where reduced power consumption is advantageous. For example, process 136 could be implemented in a wireless security access system and even a wireless headset for a cellular or conventional telephone.
[0041] Microcontroller 22 may be programmed to improve the quality of analog playback from digitally transmitted signals. Interference may be reduced or eliminated by transmitting data transmitting data over a first channel and then immediately transmitting the data over a second, different channel, regardless of whether the receiving intercom request missing data. The second transmission may be used to repair or reconstruct any data lost or damaged in the first transmission. The first and second channels should be selected to reduce the likelihood that any interference in the transmission band of transceiver 26 will affect both channels. As seen in FIG. 8A , first channel 164 is selected to be above the minimum frequency 166 of transceiver 26 , and a predetermined distance from second channel 168 , which is less than the maximum frequency 170 of transceiver 26 . In FIG. 8A , interference 172 is not affecting transmissions on either first channel 164 or second channel 166 . In FIG. 8B , interference 172 is on or near second channel 166 . First channel 164 is free from interference 172 . Accordingly, any lost data in digital transmissions over second channel 166 could be repaired by the transmissions occurring over on first channel 164 .
[0042] Microcontroller 22 may thus implement a sound quality improvement process 174 for increasing the clarity of transmissions between two or more paired intercoms 10 . Transmission improvement process 174 commences with a valid transmission between two intercoms 176 . Intercoms 10 then select the two channels for data transmission 178 (and the channel selection results are shared between intercoms 10 ). The first and second channels may chosen in advance by microcontroller 22 using a lookup table 180 containing a list of pairs of channel numbers. Microcontroller 22 may automatically select the channel pair, or the channel pairs may be factory installed and selected by a dipswitch. Automatic selection of the channel pair can be achieved by generating a random number in microcontroller 22 and then using the number to select the channel pair from look-up table 166 . Alternatively, the channel pair could be selected by using the security ID generated or stored by intercom 10 to select a channel set. Table 1 below contains a list of 10 sets of channel pairs that may be selected by microcontroller 22 in the 902-937 Mhz band, with 3 Mhz channel spacing.
TABLE 1 Channel Set No. 1 st channel 2 nd channel 1 902 910 2 905 913 3 908 916 4 911 919 5 914 922 6 917 925 7 920 928 8 923 931 9 926 934 10 929 937
[0043] Once the channels are selected and shared 178 , transceivers 26 of intercoms 10 are set to transmit and receive on the designated channel set. When data is received over the first channel 184 , microcontroller 22 checks the data integrity 186 . If data is good at step 186 , more data may be received at step 184 . If the data is damaged, transceiver 26 is set to the second channel 188 so that intercom 10 may receive the redundant transmission of data sent over the second channel 190 . The missing or damaged data packets received in the first transmission at step 184 are then extracted 192 from the data received in the second transmission over second channel at step 190 . The extracted packets are then assembled 194 with the data received at step 184 to form an error data stream. Transceiver 26 is reset back to the first channel 196 (so that more data may be received at step 184 ), and the repaired data from step 194 is played back 198 by the receiving intercom 10 . In this manner, the sound quality of transmitted signals is improved by repairing or replacing data that would have been otherwise lost in transmission. It should be recognized that sound quality improvement process 174 may be implemented in any digital transmitting and receiving device having a digital transceiver and associated microcontroller where reduced power consumption is advantageous. For example, process 174 could be implemented in a wireless security access system, a digital walkie-talkie system, or even in a wireless headset for a cellular or conventional telephone.
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A wireless intercom having a microcontroller that is programmed to place the intercom into a power saving sleep mode unless actively receiving or transmitting signals. The microcontroller of the intercom is interconnected to a transceiver for sending and receiving digital data packets, and to a codec for converting the digital packets to analog sound signals, and vice versa. The intercom receives digital transmission of data over a first channel and then corrects any errors in the digital data using a retransmission of the digital data over a second channel that is sufficiently spaced apart from the first channel to avoid the possibility of interference affecting both the first and second channels.
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BACKGROUND
[0001] The present exemplary embodiment relates to a composite article for a body structure of an automotive vehicle. It finds particular application in conjunction with vehicle pillars (posts), and will be described with particular reference thereto. However, it is to be appreciated that the present exemplary embodiment is also amenable to other similar applications.
[0002] Pillars are generally the vertical supports of the greenhouse of an automotive vehicle. Pillars can be referred to via letters such as A, B, C or D pillar, as referenced from the front to the back of the automotive vehicle (see FIG. 1 ). Pillars are implied. Accordingly, a greenhouse having a break between windows or doors without a vertical support at that position is nonetheless assigned a letter to that location. A non-existent pillar is skipped in the naming protocol such that a two door coupe has a front A-pillar and a rear C-pillar.
[0003] External objects can impact one or several of the pillars. Therefore, vehicle pillars constitute a part of a vehicle body which requires high rigidity to effectively absorb an impact from an external object. However, in the constant struggle to achieve increased energy efficiency, a rigid but light weight pillar is desirable.
[0004] Traditionally, a front or A-pillar of an automotive vehicle includes a steel outer body panel that extends between the vehicle door and a windshield. The outer body panel cooperates with a steel inner body panel and optionally a stiffener that is interposed between the inner and outer body panels. All three components include a door flange and a windshield flange, in which the respective flanges are secured together, e.g., are welded together. A garnish is then used to seal the pillar body panels from the interior of the vehicle.
[0005] The present disclosure describes a fiber reinforced polymeric composite forming an automotive pillar garnish having high rigidity and relatively low weight.
BRIEF DESCRIPTION
[0006] Various details of the present disclosure are hereinafter summarized to facilitate a basic understanding, however this summary is not an extensive overview of the disclosure, and is intended neither to identify certain elements of the disclosure, nor to delineate the scope thereof. Rather, the primary purpose of this summary is to present some concepts of the disclosure in a simplified form prior to the more detailed description that is presented hereinafter.
[0007] According to a first embodiment, a pillar garnish component of a vehicle is provided. The pillar garnish component is comprised of an elongated body having a first layer of polyolefin and a second layer of thermoplastic polymer including at least one of synthetic and natural fibers.
[0008] According to a second embodiment, a method of making a pillar garnish component of a vehicle is provided. The method includes forming a fiber reinforced polymer shell and forming a polyolefin core and attaching the core to the shell via one of in-mold bonding or adhesion.
[0009] According to a further embodiment, an automotive vehicle including a pillar assembly is provided. The pillar assembly comprises a structural reinforcement member and an associated garnish. The garnish is constructed of an elongated polypropylene inner layer mated to a cooperatively shaped fiber filled polypropylene outer layer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The following description and drawings set forth certain illustrative embodiments of the disclosure in detail, which are indicative of several exemplary ways in which the various principles of the disclosure may be carried out. The illustrated examples, however, are not exhaustive of the many possible embodiments of the disclosure. Other objects, advantages and novel features of the disclosure will be set forth in the following detailed description of the disclosure when considered in conjunction with the drawings, in which:
[0011] FIG. 1 is a side perspective view of an automotive vehicle designating pillar locations;
[0012] FIG. 2 is a perspective view of a front (A) pillar;
[0013] FIG. 3 is a cross-section of the pillar of FIG. 2 ;
[0014] FIG. 4 is a front side perspective view of a pillar garnish of FIGS. 2 and 3 ;
[0015] FIG. 5 is a rear side perspective view of the pillar garnish of FIG. 4 ;
[0016] FIG. 6 is a cross-section taken along line B-B of FIG. 4 ;
[0017] FIG. 7 is a cross-section taken along line C-C of FIG. 4 ; and
[0018] FIG. 8 is a schematic illustration of the manufacturing process of the present disclosure.
DETAILED DESCRIPTION
[0019] With reference to FIGS. 2 and 3 , an A-pillar 200 includes an inner body panel 202 having a windshield flange 206 along one edge and a door flange 208 along a second edge. The pillar 200 further includes an outer body panel 212 interposed between a windshield flange 226 and a door flange 228 . Flanges 206 / 226 and 208 / 228 can be joined via welding.
[0020] A molding 222 overlies the exterior of the pillar 200 . A pillar garnish 230 overlies the interior of the pillar 200 and extends between the windshield 240 and the door seal 242 . Garnish 230 includes an integral garnish clip receiving projection 308 holding garnish clip 310 which mates with a cooperative passage in inner body panel 202 .
[0021] Referring now to FIGS. 4-7 , the pillar garnish 230 is depicted. The pillar garnish 230 includes a polyolefin inner stiffener layer 302 and a fiber filled polymeric outer layer 304 . The polyolefin inner stiffener layer 302 is formed to include a garnish clip receiving projection 308 holding garnish clip 310 . A door lining clip receiving projection 312 is provided to retain door mating clip 314 . Clips 310 and 314 are received within cooperative passages in the automotive vehicle body to secure pillar garnish 230 in a suitable location.
[0022] Inner stiffener layer 302 is formed to include a plurality of weight reducing cut outs (CO) such that it is discontinuous and a plurality of stiffening ridges (SR) providing reinforcement zones where desired. The cut outs are provided to judiciously reduce the weight of the polyolefin inner layer 302 . The stiffening ridges are provided to reinforce areas of inner stiffener layer 302 adjacent to the cut outs or in alternative areas in which added torsional strength is desired.
[0023] An opening 316 is provided for a speaker component assembly. Opening 316 includes adjacent passages 318 which are surrounded by radially extending stiffening ridges. Passages 318 are provided for speaker component attachment. Inner stiffener layer 302 is provided with projecting members 320 and 322 which facilitate pillar locating to ensure fit and finish to the instrument panel. Inner stiffener layer 302 can also be provided with other suitable attachment features and passages to accommodate automotive vehicle components such as safety features, an electrical harness, etc.
[0024] Polyolefin inner stiffener layer 302 can be comprised of a material such as polyethylene, polypropylene or mixtures thereof. Polyethylene is widely regarded as being relatively tough, but low in stiffness. Polypropylene generally displays the opposite trend, i.e., is relatively stiff, but low in toughness. Several well known polypropylene compositions have been introduced which address the toughness issue. For example, it is known to increase the toughness of polypropylene by adding rubber particles, either in-reactor or through post-reactor blending. These materials are viable options for each of the inner stiffener layer and polymeric outer layer of the present pillar garnish. The inner stiffener layer can have a weight of about 2400 g/m 2 or greater.
[0025] Fiber filled polymeric outer layer 304 can be comprised of a thermoplastic polymer selected from compounds including but not limited to polyester, acrylonitrile butadiene, styrene acrylic, EVA, fluoroplastics, polyamides, polybutadiene, polybutylene, PET, polystyrene, polyurethane, polyvinyl acetate, polycarbonate, polypropylene, polyethylene and mixtures thereof. The polymeric outer layer further includes at least one of synthetic or natural fibers. The fiber filled polymeric outer layer can have a weight of about 600 g/m 2 or less.
[0026] The fiber utilized can be synthetic, such as glass, aramid, carbon, polymeric, etc. or it can be a natural, such as flax, hemp, jute, kenaf, banana, pineapple, sisal, cotton, hair, wood, etc. Natural fiber may be desirable because of its sustainability and environmental friendliness. The fibers can be in the form of a woven fabric or can be in the form of chopped fiber or a combination thereof.
[0027] The polyolefin inner layer can be extruded, compression molded, or injection molded. The fiber filled thermoplastic outer layer can be similarly injection molded, compression molded, or extruded in sheet form. Moreover, the fiber filling can be intimately mixed with the thermoplastic polymer and injection molded or the fiber filling can be laminated with a thermoplastic resin sheet and thermo-compression formed. During the heated compression molding, the thermoplastic material and optionally the fibers are at least partially melted to create a matrix that binds the fibers within the thermoplastic material.
[0028] It is noted that the disclosure also contemplates molding, extruding or thermoforming the inner stiffener layer and the outer fiber reinforced layer together.
[0029] If chopped filling is used, the fibers can have a length, for example, within the range having a lower limit of ⅛ inch and an upper limit of ½ inch. The diameter of the chopped fibers or the woven sheet fibers can be for example, within the range having a lower limit of 10.mu·m and an upper limit of 100.mu·m. However, the length and diameter of the fiber employed in the fiber reinforced polymeric composite is not particularly restricted.
[0030] Furthermore, the fibers may include a surface coating and/or treatment to address moisture absorption, compatibility with the polymeric matrix, and microbe susceptibility, as examples.
[0031] The fiber filling can also exhibit different moments of plane area along its lengthwise direction. In order to minimize weight and to meet the strength requirements better in certain areas, it may be made thinner in certain areas or indeed it may have larger distances between its outer surfaces in comparison with other portions.
[0032] Similarly, in order to ensure good strength characteristics with low weight, it may be desirable for the fibers to be oriented in the principal normal stress directions. This means that the fibers can be oriented perpendicularly to the direction from which a possible impact on the vehicle pillar is to be expected.
[0033] The fiber reinforced polymeric outer layer can be formed from a composition that includes at least about 30 wt % fiber, based on the total weight of the composition of thermoplastic polymer as the matrix resin. The ratio between thermoplastic material and fibers can be within the range from 30:70 to 70:30, or can be from 30:70 to 50:50, and can be near 50:50.
[0034] In a particular embodiment, the matrix thermoplastic polymer can contain a modifier. Typical modifiers include, for example, unsaturated carboxylic acids, such as acrylic acid, methacrylic acid, maleic acid, itaconic acid, fumaric acid or esters thereof, maleic anhydride, itaconic anhydride, and derivates thereof. In another particular embodiment, the matrix thermoplastic polymer does not contain a modifier. In still yet another particular embodiment, the thermoplastic polymer further includes a grafting agent. The grafting agent includes, but is not limited to, acrylic acid, methacrylic acid, maleic acid, itaconic acid, fumaric acid or esters thereof, maleic anhydride, itaconic anhydride, and combinations thereof.
[0035] The matrix thermoplastic polymer, and in fact, the polyolefin forming the inner stiffener layer may further contain additives commonly known in the art, such as dispersant, lubricant, flame-retardant, antioxidant, antistatic agent, light stabilizer, ultraviolet light absorber, carbon black, nucleating agent, plasticizer, and coloring agent such as dye or pigment. Diffusion of additive(s) during processing may cause a portion of the additive(s) to be present in the fiber.
[0036] The pillar garnish can have a flexural modulus of at least about 270,000 psi. Advantageously, the fiber filling reduces the weight of the garnish without significantly sacrificing strength.
[0037] The pillar garnish 230 can further include a decorative surface layer 324 . The decorative surface layer may be a top coat, a fabric material, a fleece material or a plastic film, as examples. Applying the decorative surface layer can be carried out simultaneously with formation of the substrate or it may be carried out in a subsequent step.
[0038] If an adhesion method is utilized in the manufacture of the pillar garnish, a glue layer 326 , such as a polyamide, may be provided intermediate the inner stiffener layer 302 and the outer fiber reinforced layer 304 . Hot melt adhesion is also contemplated.
[0039] The pillar garnish may also be associated with a B-pillar or any other pillar of a vehicle. At least in the case of a B or a C pillar the pillar garnish can be formed with passages and/or reinforced fastening portions corresponding to the position of a vehicle's mechanical elements, such as seat belts, sun visors, AV and/or HVAC equipment.
[0040] FIG. 8 provides a schematic illustration of one feasible manufacturing methodology. At step 400 a thermoplastic polymer board is provided which is assembled with a woven fiber fabric at step 402 to create a preform. The preform is introduced to a heating step 404 to achieve at least the softening point for the polymer. The preform is then compression molded at step 406 to yield an unfinished part which is trimmed as necessary at step 408 . The finished fiber reinforced outer layer is available at step 410 . An injection molding step 412 can be used to produce the polyolefin inner part at step 414 . The part at step 410 and the part at step 414 can then be adhesively joined to form the garnish. In-mold trimming of the garnish edges can be performed as appropriate. It is also envisioned that the fiber reinforced outer layer and the polyolefin inner layer are simultaneously in-mold shaped and bonded.
[0041] The disclosed multi-layered panel meets the requirements of its various intended applications, including strength, self-stability, stiffness, noise insulation, temperature resistance, and the like, while also being cost economical and may be produced in a simple and uncomplicated manner and may also be disassembled or broken down for recycling purposes.
[0042] The above examples are merely illustrative of several possible embodiments of various aspects of the present disclosure, wherein equivalent alterations and/or modifications will occur to others skilled in the art upon reading and understanding this specification and the annexed drawings. In particular regard to the various functions performed by the above described components (assemblies, devices, systems, and the like), the terms (including a reference to a “means”) used to describe such components are intended to correspond, unless otherwise indicated, to any component which performs the specified function of the described component (i.e., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the illustrated implementations of the disclosure. In addition, although a particular feature of the disclosure may have been illustrated and/or described with respect to only one of several implementations, such feature may be combined with one or more other features of the other implementations as may be desired and advantageous for any given or particular application. Also, to the extent that the terms “including”, “includes”, “having”, “has”, “with”, or variants thereof are used in the detailed description and/or in the claims, such terms are intended to be inclusive in a manner similar to the term “comprising”.
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An automotive vehicle including a pillar assembly. The pillar assembly comprises a structural reinforcement member and an associated garnish. The garnish is constructed of an elongated polypropylene inner layer mated to a cooperatively shaped fiber filled outer layer.
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BACKGROUND OF THE INVENTION
This invention relates to sewing machine attachments and more particularly to attachments for use in sewing fabric tubes that have a consistently uniform diameter and cross-sectional configuration throughout their entire length.
One of the major problems in the fabric sewing art is to sew a straight and even seam on any length of fabric tube particularly where the tube is of a small diameter and is used to produce spaghetti-type straps. This problem is particularly acute in the case of bias cut fabric strips utilized for many fabric tubular members because of their stretchability and flexibility in sewing articles of complex configurations. When the fabric strips are cut on the bias, i.e. at a 45° angle to the grain of the fabric, the fabric tends to act like the well-known Chinese finger trap made of woven grasses or the like whereby the harder one pulls, the tighter it gets. Further, some loosely woven fabrics that can be made into desirable tubing are particularly difficult to control during sewing when cut on the bias. One important factor in home as well as in industrial sewing is the ability to create clothes and accessories which have a professional appearance. A further and equally important requirement is for the operator to be able to use a relatively simply constructed and easy to manipulate sewing machine attachment. In other words, the attachment must be a practical piece of equipment that can be readily affixed to a standard sewing machine and then operated without the user having to resort to looking up and following a complex set of operating instructions. Such an attachment is provided by the instant invention.
Various prior art devices have not proven entirely satisfactory in providing the simplified sewing machine attachment required by sewing machines used both commercially and at home for sewing simple, consistently uniform and attractive tubular fabric products. The reason for such inadequacy resided primarily in their complex design and the high level of skill required for their successful use. Further, most prior art devices were singular use devices, i.e. they were limited to producing but a single sized finished tubular product.
Prior art sewing machine attachments, such as those illustrated in U.S. Pat. Nos. 983,528, 2,570,012, 2,534,534 and 2,818,826 are representative of such complexity and the difficulties involved in utilizing such equipment. For example, they include special arbor-like elements for producing on the same equipment single size fabric tubing seamed on the outside and then inverted to conceal the seam. Thereafter, a filler material is inserted in the inverted tubing. Other sewing machine attachments for producing tubular or folded and seamed fabric items, such as are shown in U.S. Pat. No. 973,530, require extreme care in threading the cloth into and through the attachments because of the close tolerances required in precisely overlapping the edges of the fabric to be seamed. Moreover, the attachment shown in this patent is no readily adaptable for sewing differently sized tubular fabrics and in one embodiment it employs a horizontally swinging curved sewing needle that would appear to be difficult to control in sewing a straight seam. U.S. Pat. No. 2,314,202 discloses a further complex sewing machine attachment for producing biased or helically seamed tubing wherein the seam is inverted for appearance sake.
The intricate sewing machine attachment of U.S. Pat. No. 1,836,742 is intended for use in producing blind stitch piping wherein the fabric edges are folded several times and then stitched to form piping with the stitches being visible on one side only.
The several fabric guides of U.S. Pat. No. 1,157,384 are of a convoluted cross-section and not readily adaptable for producing simple fabric tubing.
Finally, the lack of a simple and readily useable sewing machine attachment for producing consistently uniformly dimensioned tubular fabric is further illustrated at pages 60 and 61 of a sewing machine manual published by the Singer Sewing Machine Company, entitled "Singer Electric Sewing Machine -206K43", copyright 1952-53. The pages referred to in this manual disclose a sewing machine attachment for sewing binding materials onto a piece of cloth wherein a multi-slotted binding scroll is employed to cause different types of binding to encircle the cloth edge to be reinforced.
SUMMARY OF THE INVENTION
The present invention concerns an apparatus and a method for consistently forming fabric tubes of substantially uniform cross-sections and diameters throughout their length from various sizes and types of fabric without the need for multiple and complex sewing machine fixtures. After being formed, the tubes, depending upon the use to which they are to be put, can then be readily and easily inverted to conceal the previously formed seam even when the fabric material has been cut on the bias or against the grain. After being formed such tubes can then be filled with cording or other suitable material while being inverted. An example of the type of instrumentality that may be used for inversion purposes is shown in my prior U.S. Pat. No. 4,620,649. A fabric tube of uniform cross-section and diameter throughout, as produced by the present invention, is most desirable in order to be able to fill the same with uniformly sized reinforcing expansion material and also for the sake of appearance. The present invention is further useful in the creation of bias cut tubing of uniform diameter, which is required in many instances because of its pliability and versatility in cornering and piping.
In contrast to prior sewing practice where the aligned cut edges of a length of fabric have been used to guide the fabric past the seaming needle to form the tube, the instant invention utilizes in an improved fashion the fold of the fabric along with a unique sewing machine attachment guide element to control sewing of the seam uniformly and evenly from one end of the fabric to the other. In the past, any unevenness in the cut fabric edges, when used as a seam sewing guide, has shown up in irregular uneven seams which not only detracted from the appearance of the final product but also presented problems at the time when an attempt was made to stuff the tubing with the usual filler cord.
In summary, it is the primary purpose of this invention to provide an improved, readily adjustable sewing machine attachment and a sewing method that are easy to use by professional and nonprofessional sewers, such as seamstresses, tailors, upholsterers and homemakers and the like for consistently producing fabric tubing of substantially uniform diameter from one end of a given length of fabric to the other in different sizes and from various materials including loosely woven materials and fabrics cut on the bias.
Other features and advantages of the instant invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of one embodiment of the sewing machine attachment of the instant invention with parts broken away, other parts omitted and still other parts being shown in dotted lines;
FIG. 1a is a side elevational view with parts broken away of the attachment of FIG. 1 when taken generally along line 1a--1a thereof, this Figure illustrating how the slope of the various attachment guide elements in the area closest to the presser foot and sewing zone advantageously direct the top and bottom layers of the fabric uniformly and evenly under the presser foot and into the sewing zone;
FIG. 2 is a top plan view of another embodiment of the invention;
FIG. 3 is a side elevational view of the embodiment shown in FIG. 2 when taken along line 3--3 thereof;
FIG. 4 is an end elevational view of the attachment of FIG. 3 when taken along the line 4--4 thereof;
FIG. 5 is an enlarged and fragmentary elevational view with parts omitted when taken within the circumscribing circle 5 of FIG. 3 and illustrates in a manner similar to FIG. 1a passage of the successive portions of the fabric uniformly and evenly into the sewing zone;
FIG. 6 is a top plan view of one form of interior wrap around guide that can be used with the sewing machine attachment of FIG. 2;
FIG. 7 is a top plan view of one form of an outer guide housing that can be used in conjunction with the guide of FIG. 6; and
FIG. 8 is a diagrammatic illustration of the basic and successive steps involved in practicing the method of the instant invention.
DETAILED DESCRIPTION OF THE INVENTION
With further reference to the drawings, wherein preferred embodiments of the invention are depicted and particularly FIGS. 1 and 1a, it will be observed that the sewing machine attachment 2 of the invention can be used with various types of sewing machines by being connected to a standard presser foot 4 mounted over the usual sewing machine bed plate 6 by way of a sewing machine presser shaft or bar 8. Attachment 2, the various parts of which can be readily made of metal, plastic or combinations thereof, is generally comprised of a folded fabric guide housing 12 provided with a fabric receiving or enclosing U-shaped channel section or portion 13 formed by upper and lower legs 14 and 16 and a curved wall or web 18. Located within the channel section 13 and intermediate to the legs 14 and 16 is a fabric wrap around guide that can take the form of plate 22 having an arcuate cutaway portion 24 which along with a similar cutaway portion 26 in the top leg 14 of housing 12 facilitates the insertion or threading of a length of fabric 28 to be formed into tube through attachment 2.
In a preferred embodiment of the invention guide 22 is provided with a forwardly projecting finger segment 30 for initially engaging and guiding the fabric piece 28 cut on a bias 29 through housing 12. This finger segment 30 facilitates the entry of fabric 28 into attachment 2 by readily engaging the fold or crease 32 put in the middle of fabric 28 by the operator as the operator progressively feeds the folded cloth or fabric to and through the attachment toward the presser foot 4 and machine feed dog (not shown). Although not required, the top leg 14 of the housing 12 can be fitted with slot 17 through which the operator can insert a pin 17a to contact and push the leading parts of the fabric forward during the initial threading of the fabric through the attachment 2. Upper leg 14 of housing 12 is advantageously further provided with an upraised guide lip 34 for use in guiding the leading errant edge of the to fold of the bias cut fabric 28 snugly between the inner plate 22 and upper leg 14 of the housing 12.
As further indicated in the drawings, reference being made particularly to FIGS. 1 and 1a, the extensions 42 of housing legs 14 and 16 and extension 44 of guide 22 are secured together in sandwich fashion along with various small spacer plates 46 in the angular recess 48 of the transition member 50 by means of suitable screws or rivets 52.
The various embodiments of the invention further contemplate that attachment 2 will be adjustably affixed to the presser foot 4 in such a fashion that it can be readily and conveniently moved as a unit crossways to the sewing seam path projected by dotted line 51 on the fabric in FIG. 1 in order to permit the attachment 2 to be used to sew various sizes of tubes including the small and difficult to sew spaghetti sized fabric tubes. It also allows the use of various types of closely or loosely woven fabrics. This is accomplished by means of a slotted slide bar 54 welded or otherwise secured to or integrally formed with transition member 50, the bar being movably mounted within channel 56 of the presser foot bracket 58 by means of a locking screw 60 adjustably inserted in the slot 61 of slide bar 54 or a similar securing device well known in the art. If desired and for ease of manufacture transition member 50, slide bar 54 and bracket 58 can be injection molded in a manner known in the art. With further reference to FIG. 1, it will be observed that presser foot 4 attached to the sewing machine presser bar or shaft 8 includes a leg bracket 62 for use in affixing the same to presser shaft 8. The bottom extremity of leg bracket 62 is pivotally attached in the usual fashion to the cloth contacting part of presser foot 4. Presser foot 4 further includes the standard needle opening 66 for sewing machine needle 68 located in sewing zone Z above the usual feed dog (not shown).
One particularly significant and advantageous feature of the sewing machine attachment 2 of this invention concerns the disposition of the fabric engaging edge 70 of the fabric wrap around guide 22 relative to the arcuate web 18 of channel section 13 for guide housing 12. As indicated in FIGS. 2 and 6 the linearly extending edge portion 70, rounded so as not to catch on the cloth, is slightly tapered or inclined at a small angle on the order of about 1° to an axis A--A. This axis A--A generally parallels the midpoint of the curved wall portion or web 18 of housing 12 as well as the seam that is to be stitched along projected path 51 that in turn not only parallels axis A--A but is also linearly aligned with sewing needle 68. Accordingly, when guide 22 is fitted intermediate to the legs 14 and 16 and within channel section 13 of housing 12, the fabric engaging edge 70 will gradually converge with but fail to fully contact the web 18 of housing 12. The closest point P (see FIG. 2) of convergence of web 18 and folding edge portion 70 occurs just before the successive portions of the folded fabric leave the attachment 2 and pass below the presser foot 4 and into sewing zone Z. This permits web 18 of housing 12 and fabric engaging edge 70 of guide 22 to fully cooperate in consistently holding successive increments of the folded portion 32 of the fabric 28 snugly against the edge 70 of the guide 22 as they slide smoothly along the guide out of attachment 2 and into the sewing zone Z under full control. This controlled escort of the fabric 28 means that the distance d from seam path 51, that ultimately becomes the final uniform seam 51a, to the folded portion 32 of the fabric, will be maintained throughout tube sewing once it is set at a fixed value pursuant to the desired fabric tube diameter. In other words, this distance d will remain substantially constant as successive incremental portions of the fabric are fed to and engaged by the feed dog (not shown) along seam path or line 51 after passing through and out of attachment 2 under presser foot 4 and needle 68 operating in the presser foot opening 66 and regardless of any irregularities in the lapped edges 80 of the fabric.
A further advantageous feature of the sewing machine attachment 2 of the invention, and as particularly indicated in FIGS. 1a and 5, resides in the manner in which the trailing edges x and y of housing and guide extensions 42 and 44 respectively, i.e. those portions of members 12 and 22, which are located closely adjacent the sewing zone Z, slope or, are inclined downwardly. In the case of the attachment shown in FIG. 1, this is accomplished by bending down the trailing edge portions x and y from the normal plane of attachment 2 which is somewhat elevated by virtue of the two support legs 82 (only one of which is shown) for housing 12. In the attachment embodiment shown in FIGS. 2-7, which is to be described hereinafter, the main body portions of guide housing 12' and guide plate 22', are given a continuous gentle slope including the trailing edge portions x and y thereof by virtue of the downwardly bent frontal ramp 84 of this embodiment of the invention. This trailing edge arrangement for the guide housing and plate is additional insurance that the top and bottom layers of successive portions of the fabric strip 28 will be uniformly and evenly introduced into the sewing zone. Also, the consistency of cross-section in the finished tubular fabric is preserved by preventing the top and bottom fabric layers from pulling against each other due to the differential distance these layers must travel from the presser foot 4 to the sewing zone Z.
The embodiment of sewing machine attachment shown in FIGS. 2-7 will now be described. It is similar in most respects to that depicted in FIGS. 1 and 1a. It differs from the embodiment of FIGS. 1 and 1a primarily in the manner in which housing 12' and guide 22' are attached to the transition member 50', the previously described fashion in which the trailing portions x and y of housing 12' and guide 22' are sloped to meet bed plate 6 and the type of knurled shoulder screw 63 used to lock attachment 2 to the presser foot 4.
Accordingly, for ready reference purposes, the elements of FIGS. 2-7, that generally correspond to similar elements in FIGS. 1 and 1a have been identified and distinguished by prime reference numerals to the extent practical. Guide housing 12' can be formed from a bent piece of metal to include top and bottom leg extensions 42'. The leg extensions 42' of bottom leg 16' includes angular and arcuate cutaway segments 88 and 90 as well as an elongated perforation 86. Leg extension 42' of leg 14' is provided with similar cutaway segments 88a and 90a and a perforation 86a. Leg extension 44' of inner guide plate 22', which likewise can be formed from a piece of metal, contains circular perforations or openings 92. The purpose of the perforations and cutaway sections will now be discussed in connection with the attachment of housing 12' and guide 22' to the transition member 50' which can be made of any suitable plastic material. With guide 22' properly arranged and held within housing 12' so that edge 70' of guide 22' and web 18' of housing 12' will converge without contacting, as previously described, leg extensions 42' and 44' thereof are introduced into suitable injection molding equipment. While positioned in such equipment transition member 50' is shaped into the desired configuration in a fashion well known in the art. During the same molding operation plastic parts of transition member 50' will surround the housing 12' and guide 22' to become molded about housing 12' and guide 22' as well as being permanently embedded in the various perforations and cutaway sections of the same leg extensions in the manner shown in FIG. 2 thereby firmly anchoring the housing 12' and guide 22' to the transition member 50'.
A separately formed combination slide bar 54' and connector arm 55 may be affixed by rivets 94 or the like to the extension 96 of the molded transition member 50' for adjustably mounting the attachment of FIG. 2 to the presser foot 4 in a fashion similar to the embodiment of the invention of FIG. 1, i.e. crossways to the presser foot 4. As previously noted in connection with the attachment 2 of FIG. 1, the transition member 50', slide bar 54' and connector arm 55 of attachment 2' all can be injection molded or manufactured in any suitable manner well known to those skilled in the art.
From the above description it will now be evident, reference being made especially to FIG. 8 along with FIG. 1, that a simplified piece of equipment, as well as a simplified sewing method, has been developed for producing on a consistent basis uniformly sized fabric tubing in various sizes and from a wide assortment of differently cut fabric materials including loosely woven materials. The seamstress, tailor, upholsterer and home-maker, with one of the embodiments of the sewing machine attachment in place merely has to select and cut a given length of fabric 28 which can be cut on the bias. Next, an intermediate portion and preferably the middle portion of the fabric is folded along its length in a folding zone F and then progressively and incrementally fed with the two free marginal edges of the fabric registered and overlapped from the folding zone F into and through the housing 12 or 12' and into engagement with guide 22 or 22' in a guide zone G. The folded fabric is next directed from the guide zone G to a sewing zone Z where the fabric 28 is engaged by the usual feed dog and reciprocating needle. Once the fabric is engaged by the feed dog all the operator has to do is to continue to direct the folded edge 32 of the fabric to the guide 22 or 22' which has now taken over automatic control of the feeding of the fabric to the sewing needle while keeping the cut edges in registry. As the guide 22 or 22' engages the fabric it will maintain the preselected distance d between fabric fold 32 and fabric sewing path or line 51, that is linearly aligned with the sewing needle, at a fixed and constant value as the successive increments of the fabric are presented to the needle until the full length of fabric is seamed in a uniform and even manner. In other words, if the preselected distance d is set at 1" (2.54 cm), this same distance will prevail between the folded edge of the fabric and the finished seam 51a consistently for substantially the entire length of the finished tube T as shown in FIG. 8. Using the novel sewing machine attachment of the invention, the sewing machine operator no longer has to rely on frequently uneven lapped marginal edges of a fabric as an imperfect guide medium for seaming fabric tubing.
Advantageous embodiments of the invention have been shown and described, it will be obvious that various changes and modifications may be made thereto without departing from the spirit and scope thereof as defined in the appended claims.
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Apparatus and method for sewing a length of fabric into seamed tubing that has a consistently uniform diameter and cross-sectional configuration along substantially its entire length, wherein simplified guide means and steps are employed for controlling the full movement of the length of the fabric forming the tubing to and through a sewing zone.
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TECHNICAL FIELD
[0001] The present invention relates to a heating cooker.
[0002] BACKGROUND ART
[0003] Conventionally, there has been a heating cooker which has a main body casing and a door pivotably mounted to the main body casing and in which an annular packing seal for sealing between the main body casing and the door is attached to the rear surface side of the door (refer to, for example, JP 2000-46192 A).
[0004] In the above heating cooker, the packing seal comes in contact with a front panel of the main body casing from the hinge side of the packing seal when the door is being closed, and a load due to the elastic deformation of the packing seal is applied first to the hinge side of the door in comparison with the side of the packing seal opposite to the hinge. Accordingly, there is a problem that the load due to the elastic deformation of the packing seal on the door becomes nonuniform in a state in which the door is closed, and a gap, which is located between the front panel of the main body casing and the door, becomes wider on the side opposite to the hinge, resulting in an uniform gap between the front panel of the main body casing and the door and causing an unstable sealing state. Therefore, it is concerned that the door freely opens when the internal pressure of the cooker rises, and it is necessary to securely lock the closed door by means of a mechanism such as a latch lock.
[0005] It is an object of the present invention to provide a heating cooker capable of keeping a reliable sealing state by uniforming a gap between the front panel of the main body casing and the door in a state in which the door is closed without employing a mechanism such as a latch lock for locking the closed door.
DISCLOSURE OF THE INVENTION
[0006] In order to achieve the above object, there is provided a heating cooker comprising:
[0007] a main body casing having a front panel;
[0008] a door connected to one side of the front panel of the main body casing via a hinge so as to open and close; and
[0009] an annular packing seal provided at the door or the front panel so as to be located between the door and the front panel, wherein
[0010] a portion on the hinge side of the annular packing seal is positioned closer to a front surface side than a portion opposite to the hinge side of the annular packing seal when the annular packing seal is provided at the door, or
[0011] the portion on the hinge side of the annular packing seal is positioned closer to a back surface side than the portion opposite to the hinge side of the annular packing seal when the annular packing seal is provided at the front panel.
[0012] According to the above construction, by providing the annular packing seal at the door and positioning the portion on the hinge side of the annular packing seal closer to the front surface side than the portion opposite to the hinge side of the annular packing seal, even if the hinge side of the annular packing seal first comes closer to the front panel of the main body casing when the door is being closed, the whole annular packing seal concurrently comes in contact with the front panel of the main body casing immediately before the door is closed, and the whole annular packing seal is elastically deformed roughly similarly in the state in which the door is closed. Otherwise, by providing the annular packing seal at the front panel of the main body casing and positioning the portion on the hinge side of the annular packing seal closer to the back surface side than the portion opposite to the hinge side of the annular packing seal, even if the hinge side of the annular packing seal first comes closer to the front panel of the main body casing when the door is being closed, the whole annular packing seal concurrently comes in contact with the front panel of the main body casing immediately before the door is closed, and the whole annular packing seal is elastically deformed roughly similarly in the state in which the door is closed. With this arrangement, a load due to the elastic deformation of the packing seal is uniformly applied to the whole door. Therefore, the gap between the front panel of the main body casing and the door is uniformed in the state in which the door is closed without employing a mechanism such as a latch lock for locking the closed door, and a reliable sealing state can be maintained.
[0013] In one embodiment of the invention, the annular packing seal has a roughly identical cross section shape.
[0014] In one embodiment of the invention, when the door is closed, a squeeze dimension of the portion on the hinge side of the annular packing seal is smaller than a squeeze dimension of the portion opposite to the hinge side of the annular packing seal.
[0015] According to the above embodiment, although the hinge side of the annular packing seal first comes closer to the front panel of the main body casing when the door is being closed, by making the squeeze dimension due to the contact of the portion on the hinge side of the annular packing seal provided at the door (or the front panel) smaller than the squeeze dimension of the portion opposite to the hinge side, the whole annular packing seal concurrently comes in contact with the front panel of the main body casing immediately before the door is closed, and the whole annular packing seal is elastically deformed roughly similarly in the state in which the door is closed. With this arrangement, the load due to the elastic deformation of the packing seal is uniformly applied to the whole door.
[0016] As is apparent from the above, according to the heating cooker of the present invention, the gap between the front panel of the main body casing and the door is uniformed in the state in which the door is closed without employing a mechanism such as a latch lock for locking the closed door, and a reliable sealing state can be maintained.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a perspective view showing an external appearance of a heating cooker of one embodiment of the present invention;
[0018] FIG. 2 is a perspective view showing an external appearance in a state in which the door of the heating cooker is opened;
[0019] FIGS. 3A , 33 and 3 C are a front view, a plan view and a side view of the essential part including the door of the heating cooker;
[0020] FIG. 4 is a side view showing a state on the way of opening or closing the door of the heating cooker;
[0021] FIG. 5 is a sectional view of the essential part of the door viewed from the line IV-IV of FIG. 4 ; and
[0022] FIG. 6 is a sectional view of the essential part of another door viewed from the line IV-IV of FIG. 4 .
DETAILED DESCRIPTION OF THE INVENTION
[0023] An embodiment of the heating cooker of the present invention will now be described with reference to the accompanying drawings.
[0024] FIG. 1 is a perspective view showing an external appearance of a heating cooker 1 of one embodiment of the present invention, in which a door 12 is connected to the front of a rectangular parallelepiped main body casing 10 so as to pivot roughly around its lower end side. The door 12 is provided with an operation panel 11 on the right-hand side, a handle 13 at the upper portion, and a window 14 made of a heat-resistant glass at the central portion.
[0025] FIG. 2 is a perspective view showing an external appearance of the heating cooker 1 in a state in which the door 12 is opened, where a rectangular parallelepiped heating chamber 20 is provided in the main body casing 10 . The heating chamber 20 has an opening 20 a on the front side facing the door 12 , and a side face, a bottom face and a top face of the heating chamber 20 are each formed of a stainless steel plate. Moreover, a side of the door 12 facing the heating chamber 20 is formed of a stainless steel plate. An annular packing seal 40 is attached to the rear surface side of the door 12 so as to enclose the outer periphery of the window 14 to provide a seal between the main body casing 10 and the door 12 when the door 12 is closed. By arranging a heat insulator (not shown) in the surroundings of the heating chamber 20 and inside the door 12 , heat insulation between the inside and the outside of the heating chamber 20 is achieved.
[0026] Moreover, a tray 21 made of stainless steel is placed on the bottom surface of the heating chamber 20 , and a rack 22 made of stainless steel wires for carring a cooking object is put on the tray 21 . It is noted that in the opened state the upper surface of the door 12 is roughly horizontal, and the cooking object can be temporarily placed on the door 12 when taken out.
[0027] Further, the main body casing 10 is provided with a water tank accommodating portion 100 for accommodating a water tank 30 at the left side of the heating chamber 20 . The water tank 30 is inserted into the water tank accommodating portion 100 from the front side toward the back side.
[0028] FIG. 3A , FIG. 3B and FIG. 3C show a front view, a plan view and a side view of the essential part including the door 12 of the heating cooker 1 , respectively. In FIGS. 3A through 3C , 15 , 17 , 18 and 19 denote a front panel, an arm, a guide roller and a guide arm, respectively.
[0029] FIG. 4 shows a side view showing a state on the way of opening or closing the door 12 of the heating cooker 1 . As shown in FIG. 4 , the front panel 15 of the main body casing 10 (shown in FIGS. 1 and 2 ) has a roughly square frame-like shape having the opening 20 a of the heating chamber 20 . The front end of the guide arm 19 is fixed to the lower side on both sides of the front panel 15 at a prescribed interval. The guide roller 18 is pivotably connected to the guide arm 19 . Moreover, the door 12 is supported swingably to the front panel 15 via the hinge 16 . When the door 12 is opened or closed in the direction of the arrow R, the arm 17 protrudes or retreats being guided by the guide roller 18 in accordance with the opening or closing of the door 12 . When the door 12 is opened to become roughly horizontal, the door 12 is stopped and maintained in a roughly horizontal state by a stopper mechanism (not shown) constituted of the arm 17 and the guide arm 19 .
[0030] Next, FIG. 5 shows a sectional view of the essential part of the door 12 viewed from the line IV-IV of FIG. 4 . It is noted that FIG. 5 shows only a door frame 41 , a door cover 42 and the annular packing seal 40 of the door 12 . It is noted that the reference numeral 15 indicated by the dashed lines denotes the front panel.
[0031] As shown in FIG. 5 , the door cover 42 is fit on the outer peripheral of the door frame 41 on the main body casing side (right-hand side of FIG. 5 ). Moreover, the packing seal 40 is attached so as to be partially held between the door frame 41 and the door cover 42 .
[0032] The annular packing seal 40 has a roughly identical cross section shape throughout the entire periphery. The annular packing seal 40 has a cross section shape having a curved portion 40 a curved in a circular arc shape, a bent portion 40 b that extends bending from the outer peripheral side of the curved portion 40 a, a base portion 40 c that extends from the inner peripheral side of the bent portion 40 b frontward (left-hand side in FIG. 5 ) and a groove portion 50 provided on the outer peripheral side of the base portion 40 c. By fitting the base portion 40 c of the annular packing seal 40 on the door frame 41 and inserting the door cover 42 into the groove portion 50 , the base portion 40 c of the packing seal 40 is fixed held between the door frame 41 and the door cover 42 .
[0033] Then, as shown in the two enlarged views (views enclosed by the circles) of FIG. 5 , a hinge 16 side (lower side in FIG. 5 ) of the annular packing seal 40 is positioned closer to the front surface side (left-hand side in FIG. 5 ) by a dimension L (e.g., 0.5 mm) than the side (upper side in FIG. 5 ) opposite to the hinge 16 . In this case, the left-hand side and the right-hand side of the annular packing seal 40 are inclined to the front surface side from the upper side to the lower side.
[0034] According to the heating cooker of the above construction, the annular packing seal 40 of the roughly identically cross section shape is provided at the door 12 , and the hinge 16 side of the annular packing seal 40 is positioned closer to the front surface side than the side opposite to the hinge 16 . Therefore, even if the hinge 16 side of the annular packing seal 40 first comes closer to the front panel 15 of the main body casing 10 when the door 12 is being closed, the whole annular packing seal 40 roughly concurrently comes in contact with the front panel 15 of the main body casing 10 immediately before the door 12 is closed, and the whole annular packing seal 40 is elastically deformed roughly uniformly in the state in which the door 12 is closed. With this arrangement, a load due to the elastic deformation of the packing seal 40 is uniformly applied to the whole door.
[0035] Therefore, the gap between the front panel 15 of the main body casing 10 and the door 12 is uniformed in the state in which the door 12 is closed without employing a mechanism such as a latch lock for locking the closed door 12 , and a reliable sealing state can be maintained.
[0036] Although the heating cooker, in which the annular packing seal 40 is made to have the roughly identical cross section shape and the hinge 16 side of the annular packing seal 40 provided at the door 12 is positioned closer to the front surface side than the side opposite to the hinge 16 , has been described in the above embodiment, it is acceptable to provide an annular packing seal having a roughly identical cross section shape at the front panel and to position the hinge side of the packing seal closer to the back surface side than the side opposite to the hinge.
[0037] Moreover, it is acceptable to provide an annular packing seal that does not have a roughly identical cross section shape at the door (or the front panel of the main body casing) and to make a squeeze dimension due to the contact of the annular packing seal on the hinge side smaller than a squeeze dimension due to the contact on the side opposite to the hinge.
[0038] For example, FIG. 6 shows a sectional view of the essential part of another door viewed from the line IV-IV of FIG. 4 , where the door frame 41 has the same construction as that of the essential part of the door shown in FIG. 5 except for an annular packing seal 60 and a door cover 62 .
[0039] The annular packing seal 60 has a cross section shape that is not roughly identical throughout the entire circumference. The annular packing seal 60 has a cross section shape having a curved portion 60 a curved in a circular arc shape, a bent portion 60 b that extends bending from the outer peripheral side of the curved portion 60 a, a base portion 60 c that extends from the inner peripheral side of the bent portion 60 b frontward (left-hand side in FIG. 6 ) and a groove portion 70 provided on the outer peripheral side of the base portion 60 c. By fitting the base portion 60 c of the annular packing seal 60 on the door frame 41 and inserting the door cover 62 into the groove portion 70 , the base portion 60 c of the packing seal 60 is fixed held between the door frame 41 and the door cover 62 . Then, a squeeze dimension M 2 due to the contact of the hinge side (lower side in FIG. 6 ) of the annular packing seal 62 with the front panel 15 is made smaller by AM than a squeeze dimension M 1 due to the contact of the side (upper side in FIG. 6 ) opposite to the hinge with the front panel 15 . With this arrangement, an effect similar to that of FIG. 6 is performed.
[0040] Furthermore, although the heating cooker, in which the door 12 is opened and closed via the hinge 16 on the lower side of the front panel 15 of the main body casing 10 , has been described in the above embodiment, the present invention may also be applied to a heating cooker or the like in which a door is opened and closed via a hinge on the right-hand or left-hand side of the front panel of the main body casing.
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A heating cooker comprising a body casing, a door openably fitted to the front panel of the body casing through hinges, and an annular packing ( 40 ) of the circumferentially same shape in cross section disposed between the door and the front panel. The hinge side of the annular packing ( 40 ) fitted to the door (including a door frame ( 41 ) and a door cover ( 42 )) is positioned on the front side by a dimension L from the anti-hinge side of the annular packing.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to a provisional patent application which has been assigned U.S. Serial No. 60/342,805, filed Dec. 19, 2001.
FIELD OF THE INVENTION
[0002] The present invention generally pertains to the prevention of ice dams on roofs. More specifically, but without restriction to the particular embodiment and/or use which is shown and described for purposes of illustration, the present invention relates to a method and apparatus for the prevention of ice dams which incorporates a retaining member having a melting substance disposed therein, the melting substance adapted to permeate through the retaining member for melting proximate ice.
BACKGROUND OF THE INVENTION
[0003] Ice dams are areas of ice buildup along the perimeter of a roof caused from the melting and subsequent freezing of snow and/or ice arranged on the roof. Ice dams are generally formed when a roof surface is above 32 degrees Fahrenheit and the outside temperature is below 32 degrees Fahrenheit. These conditions are favorable to encourage snow that may have collected on a roof to slowly melt and reform as ice on a perimeter of a roof.
[0004] Ice dams are particularly unfavorable because they add unwanted weight along a roofline which may promote roof fatigue leading to roof damage or failure. In addition, ice dams act as a barrier to collect more snow and ice on adjacent areas along the roof. Such a pattern makes the problem progressively worse.
[0005] Among current solutions to this problem include reinsulating the home, ventilation, chopping the ice or shoveling the snow off the roof. While such arrangements are satisfactory for their intended purpose, a need exists to develop simpler, more cost effective alternatives that provide the desired function while advancing the art.
SUMMARY OF THE INVENTION
[0006] It is a general object of the present invention to provide a method and an apparatus which prevents the formation of ice dams.
[0007] In one form, the present invention provides a permeable retaining member defining a chamber therein. A melting substance is disposed within the chamber, the melting substance adapted to permeate through the retaining member for melting proximate ice.
[0008] In another form, the present invention provides a method for preventing ice dams of roofs. In a first general step, a permeable retaining member having an opening is provided. In a second general step, the retaining member is filled through the opening with a melting substance. In a third general step, the opening is closed. In a fourth general step, the retaining member is placed in a predetermined location, the melting substance adapted to permeate through the retaining member for melting proximate ice.
[0009] Additional benefits and advantages of the present invention will become apparent to those skilled in the art to which this invention relates from a reading of the subsequent description of the preferred embodiment and the appended claims, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] [0010]FIG. 1 is an environmental view of an apparatus for the prevention of ice dams constructed in accordance with the teachings of a preferred embodiment of the present invention, the apparatus shown operatively positioned within a gutter of a home.
[0011] [0011]FIG. 2 is an enlarged prospective view of an apparatus for the prevention of ice dams of the present invention.
[0012] [0012]FIG. 3 is a cross-sectional view taken along line 3 - 3 of FIG. 2.
[0013] [0013]FIG. 4 is a view of the general steps of the preferred method of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0014] With general reference to FIGS. 1 - 3 , an apparatus for the prevention of ice dams constructed in accordance with the teachings of a preferred embodiment of the present invention will be described. With particular reference to FIG. 1, there is shown an apparatus for the prevention of ice dams 10 in accordance with a preferred embodiment of the present invention.
[0015] The apparatus for the prevention of ice dams 10 of the present invention is illustrated to generally include a permeable retaining member or sleeve 12 and a material 14 disposed therein for the melting device. The sleeve 12 is comprised of a generally flexible mesh-like material which allows the material 14 to permeate therethrough to melt ice and snow build-up. In one particular application, the sleeve is made of polypropelyne. It will be appreciated, however, that sleeve 12 may be comprised of other suitable flexible permeable materials, including but not limited to cotton.
[0016] In one particular application, the material 14 for the melting of ice comprises sodium acetate. One suitable material is commercially available from Cryotech Deicing Technology of Fort Madison, Iowa under the trademark NAAC. The sodium acetate comprises a plurality of spherical pellets. The spherical pellets provide a configuration which minimizes dust and results in even spread patterns. Those skilled in the art will readily appreciate that sodium acetate is preferred, although alternate materials may be incorporated. The melting process is an exothermic reaction that initiates upon the introduction of water to provide heat.
[0017] Turning now to FIGS. 2 and 3, sleeve 12 comprises a generally cylindrical sock-like retaining member. In one particular application, sleeve 12 is four (4) feet long and three (3) inches in diameter. Those skilled in the art will appreciate that these dimensions could vary considerably, and that the important consideration is that the apparatus 10 is configured to be suitably placed in an area of interest such as a gutter around the perimeter of a roof. Similarly, sleeve thickness 16 is preferably configured to be minimal so as to provide structural rigidity and workability while providing necessary permeability.
[0018] During assembly, sleeve 12 includes an opening 20 for disposing material 14 therethrough. When sufficient material 14 is disposed within sleeve 12 , a closure member 18 such as a tie strap, staple or other suitable device is clamped or otherwise secured around opening 20 to seal sleeve 12 . Preferably, when sleeve 12 has effectively exhausted its supply of material 14 , the sleeve 12 is removed and replaced with a new unused sleeve 12 .
[0019] In a second application, closure member 18 may be removed and material 14 may be sprinkled onto areas of interest such as driveways or sidewalks to help prevent ice and snow buildup.
[0020] Referring now to FIG. 4, in a first general step 50 the preferred method of the present invention provides a permeable retaining member 12 having an opening.
[0021] In a second general step 52 , the retaining member of the present invention is filled through the opening with a melting substance 14 .
[0022] In a third general step 54 , the opening 20 of the retaining member 12 is enclosed.
[0023] In a fourth general step 56 , the retaining member 12 of the present invention is placed in a predetermined location. The melting substance 14 is adapted to permeate through the retaining member for melting proximate ice.
[0024] While the invention has been described in the specification and illustrated in the drawings with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention as defined in the claims. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment illustrated by the drawings and described in the specification as the best mode presently contemplated for carrying out this invention, but that the invention will include any embodiments falling within the description of the appended claims.
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A permeable retaining member defines a chamber therein. The permeable retaining members has an opening to the chamber. The chamber of the retainer member is filled through the opening with a melting substance and the opening is closed. The melting substance is adapted to permeate through the retaining member for melting proximate ice in a gutter and preventing ice dams on roofs.
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FIELD OF THE INVENTION
[0001] The present invention relates to a conductive adhesive used for solder-free mounting of electronic components and a structure connected by using the same.
BACKGROUND OF THE INVENTION
[0002] In recent years, due to the increased environmental consciousness, the electrical industry now faces the movement to abolish totally lead-containing solder used for mounting of electronic components, and this movement is becoming significant.
[0003] As for lead-free mounting techniques, mounting techniques using lead-free solder have been developed keenly and a part of the development has come into practical use. However, still a number of problems remains to be solved, such as influence of a high mounting temperature on low heat-resistant components or lead-free electrodes.
[0004] On the other hand, only a few examples of lead-free mounting with the use of a conductive adhesive has been reported so far, which has the following advantages besides the aspect of lead-free mounting.
[0005] First, the processing temperature of around 150° C. is lower than the temperature for soldering, and electronic components with higher performance can be realized with low cost. Secondly, the specific gravity of a conductive adhesive is about half that of solder, so that electronic equipment can be lightened more easily. Thirdly, since the connection is not achieved by means of metal as in soldering, metal fatigue does not occur, and the reliability of mounting is excellent.
[0006] Therefore, it is expected that a revolutionary mounting process that fulfills the needs of environment, low cost, and high reliability can be realized by completing the mounting technique using a conductive adhesive.
[0007] The problem with the use of a conductive adhesive for mounting is that the adhesive strength is lower than that of solder. In particular, the strength against bending stress is about {fraction (1/10)} of that of solder, so that an electronic component with a large area to which bending stress easily is applied sometimes suffers from the separation of the electrode with the conductive adhesive at the interface, thereby causing connection failures.
[0008] Numerous attempts to improve the adhesive strength have been reported, but not even one technique is capable of achieving the same strength as that of solder. One representative example will be shown below.
[0009] As described in the publication supervised by Hiroo Miyairi, “Development of Functional Adhesives and the New Technology” (edited by CMC, Jun. 30, 1997, 194 pages), for example, a number of techniques to improve the adhesive strength by adding an organic metal called a silane coupling agent into the adhesive material, which can form a chemical bond with both resin and metal, has been reported.
[0010] However, the aforementioned techniques utilize either a dehydration reaction or a substitution reaction, so that the reactivity of the coupling agent with resin or with metal was poor, and the conditions (temperature, concentration of hydrogen ion, etc.) for optimizing the reaction could not be determined clearly, and so forth. Therefore, a considerable improvement of the adhesive strength was difficult to be achieved.
[0011] Furthermore, JP9 (1997)-176285A proposes the use of a resin with a phosphoric ester group introduced into the skeleton as a binder resin. According to this method, the functional group in the binder resin is adsorbed to the metal, so that some improvement of the adhesive strength can be achieved. However, the adsorptive power is poor in comparison with a covalent bond or a coordinate bond, so that considerably improved effects could not be obtained.
[0012] As described above, the improvement of the adhesive strength has been the key factor to make the practical use of the mounting technique using a conductive adhesive.
SUMMARY OF THE INVENTION
[0013] It is an object of the present invention to solve the conventional problems described above by providing a conductive adhesive having considerably improved adhesive strength and higher reliability against bending stress. Another object of the present invention is to provide a structure connected by using this conductive adhesive.
[0014] To achieve the above object, a conductive adhesive of the present invention includes a binder resin and a metal filler as main components, wherein the binder resin contains a functional group in its molecular chain that forms a multidentate bonding with an electrode metal after the binder resin is adhered.
[0015] A connection structure of the present invention is formed by using a conductive adhesive to connect the adhesive with an electrode electrically, wherein the conductive adhesive includes a binder resin and a metal filler as main components, and the binder resin contains a functional group in its molecular chain that forms a multidentate bonding with an electrode metal after the binder resin is adhered.
[0016] In the present invention, the multidentate bonding refers to a state in which multidentate ligands (a plurality of chelating ligands) introduced into the binder resin form coordinate bonds with the electrode metal. In other words, the adhesion is not achieved only by using the ordinary weak van der Waal's power by hydrogen bonding, but instead, a chemical bond (coordinate bond) is formed between the binder resin and the electrode.
[0017] The method of introducing a multidentate ligand into a binder resin will be explained by way of the following embodiments.
[0018] Embodiment 1
[0019] In the first method, a resin into which a desired multidentate ligand was introduced was used as an additive component in the binder resin (a reactive thinner, a hardener, or the like).
[0020] For example, a linear epoxy resin with a molecular chain into which a dicarbonyl group expressed by the chemical formula 1 below was introduced is mixed with a ring-opening catalyst, which then is applied to the surface of an electrode (Cu foil). When the resin is heated and hardened, the dicarbonyl group in the central part of the molecule forms a coordinate bond with the electrode (Cu foil) expressed by the chemical formula 2 below. Naturally, the epoxy rings at the both ends of the molecule open and form bridge bonds.
[0021] The binder resin used here includes as the main component an ordinary epoxy resin without any ligand (bisphenol A, bisphenol F. a novolak epoxy resin). The above resin into which the multidentate ligand was introduced is used by mixing and kneading so as to be contained in the binder resin in an amount between 10 and 50 wt %.
[0022] Furthermore, a ligand can be introduced into a resin to be used as a hardener in the binder resin, not only for the reactive thinner.
[0023] Embodiment 2
[0024] In the second method, a resin into which a desired multidentate ligand was introduced was used as the main component (the component contained in the largest amount) in the binder resin.
[0025] For example, a bisphenol F-type epoxy resin with a molecular chain into which a dicarbonyl group expressed by the chemical formula 3 below was introduced is mixed with a ring-opening catalyst, which then is applied to the surface of an electrode (Cu foil). When the resin is heated and hardened, the dicarbonyl group in the central part of the molecule forms a coordinate bond with the electrode (Cu foil) as in Embodiment 1.
[0026] (chemical formula 3)
[0027] The binder resin used here includes as the accessory component an ordinary epoxy resin without any ligand (a reactive thinner, a hardener, or the like). The above resin into which the multidentate ligand was introduced is used by mixing and kneading so as to be contained in the binder resin in an amount between 30 and 100 wt %.
[0028] In the adhesive and the connection structure of the present invention described above, it is preferable that the multidentate bonding is formed in a number between 2 and 4. Naturally, the number of the multidentate bonding may be larger.
[0029] Furthermore, in the adhesive and the connection structure described above, it is preferable that the resin containing a functional group in its molecular chain that forms a multidentate bonding is present in an amount between 10 and 100 wt % of the total resin.
[0030] Furthermore, in the adhesive and the connection structure described above, it is preferable that, taking the conductive adhesive as 100 wt %, the binder resin is contained in an amount between 5 and 25 wt %, and the metal filler is contained in an amount between 75 and 95 wt %. Besides, if necessary, a hardener, a hardening catalyst, a crosslinking agent, and a ring-opening catalyst for the binder resin, a dispersing agent for the metal filler, a viscosity modifier, a pH modifier, or the like may be added optionally. Therefore, in the present invention, “main components” in the “including a binder resin and a metal filler as main components” refers to the constitution in which the binder resin and the metal filler together comprise at least 90 wt % of the conductive adhesive.
[0031] Furthermore, in the adhesive and the connection structure described above, it is preferable that at least two functional groups are present, which may be the same or different, selected from the group consisting of a carbonyl group, a carboxyl group, an amino group, an imino group, an iminoacetic acid group, an iminopropionic acid group, a hydroxyl group, a thiol group, a pyridinium group, an imido group, an azo group, a nitrilo group, an ammonium group and an imidazole group.
[0032] Furthermore, in the adhesive and the connection structure described above, it is preferable that the metal filler is at least one particle selected from the group consisting of silver, silver-plated nickel and silver-plated copper. When the surface of the metal filler is silver, it does not react with the ligand of the binder resin but the ligand reacts selectively with the electrode metal. However, when the ligand of the binder resin is contained in a large amount, even if copper is used as the metal filler, for example, since not all the ligands react with the metal filler, copper also can be used as the metal filler.
[0033] Furthermore, in the adhesive and the connection structure described above, it is preferable that the binder resin is at least one resin selected from a thermoplastic resin and a thermosetting resin.
[0034] Furthermore, in the adhesive and the connection structure described above, it is preferable that the thermoplastic resin is at least one resin selected from the group consisting of a polyester resin, a silicone resin, a vinyl resin, a vinyl chloride resin, an acrylic resin, a polystyrene resin, an ionomer resin, a polymethylpentene resin, a polyimide resin, a polycarbonate resin, a fluororesin and a thermoplastic epoxy resin.
[0035] According to the invention described above, the mounting technique by the conductive adhesive with considerably improved adhesive strength can be realized.
[0036] When the conductive adhesive of the present invention and the electrode metal contact each other, the ligand of the binder resin very easily reacts with the metal, so that the ligand is coordinated quickly with the electrode metal to form a chelating ligand, i.e. a strong chemical bonding. Since the ligand is bonded to the molecular chain of the resin, the bonding also is strengthened between the binder resin and the electrode metal as well as between the conductive adhesive and the electrode metal.
[0037] The connection structure of the present invention is formed by electrically connecting the conductive adhesive of the present invention with the electrode, so that this connection structure has improved adhesive strength than conventional connection structures. Moreover, since the thermoplastic resin has excellent flexibility in comparison with a thermosetting resin, this conductive adhesive can achieve a bonding with excellent stress relaxation capability against bending stress.
[0038] The connection structure of the present invention preferably is formed by mounting a component and a substrate by using the conductive adhesive described above, which can improve the adhesive strength against bending stress even more.
[0039] The present invention can be used in place of the conventional solder, for example, as a conductive adhesive to bond a semiconductor substrate with an electronic component chip. Furthermore, the conductive adhesive also can be applied to a conductive paste by filling the conductive adhesive into through holes made in an electrical insulating base material so as to achieve electrical continuity in the thickness direction of the electrical insulating base material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0040] [0040]FIG. 1 is a cross-sectional view showing a mounted structure used for the evaluation of one embodiment of the present invention.
[0041] [0041]FIG. 2 is a cross-sectional illustrative view showing the evaluation method of one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0042] Hereinafter, the present invention will be described by way of examples with reference to drawings.
[0043] Common Experimental Method
[0044] [0044]FIG. 1 is a side view of a mounted structure used for the evaluation. A conductive adhesive 3 is screen-printed onto an electrode 2 disposed on a substrate 1 , and after an electrode 5 of a component 4 is mounted, the structure is heated in an oven at 150° C. for 30 minutes. Thus, the mounted structure was created. The material used for the substrate 1 and the component 4 was the same, and the material used for the electrode 2 and the electrode 5 was the same.
[0045] The evaluation method is shown in FIG. 2. First, pressure was provided to the component 4 from the rear side of the mounted structure created as above by using a substrate pushing jig 6 . The amount of deflection was measured when the connection resistance had risen to at least twice as much as the initial value. Then, the adhesive strength against the bending stress was evaluated. The distance between substrate fixing jigs 7 and 8 was determined to be 100 mm.
[0046] The substrate and the component will be described more in detail.
[0047] (1) Component: 0 ohmic resistance
[0048] base material; alumina or a glass epoxy substrate (3216 size) electrode specification; as shown in Table 1
[0049] (2) Substrate
[0050] base material; alumina or a glass epoxy substrate (30×150×1.6 mm) electrode specification; as shown in Table 1
[0051] (3) Conductive adhesive
[0052] filler; silver powder (85 wt %) (average particle diameter: 3 to 10 μm) binder resin (15 wt %); as shown in Table 1
[0053] Hereinafter, the respective embodiments will be explained in detail. In Examples 1 and 2, the conductive adhesive includes a material in which a functional group was introduced into a thermosetting resin. In Examples 3 and 4, the conductive adhesive includes a material in which a functional group was introduced into a thermoplastic resin.
EXAMPLE 1
[0054] Example 1 is an example, as already explained in Embodiment 1, in which a resin into which a multidentate ligand was introduced was used as an additive component (a reactive thinner).
[0055] The binder resin used for the conductive adhesive was obtained by mixing 15 wt % of a reactive thinner in which a dicarbonyl group expressed by the chemical formula 4 below was introduced into its molecular chain, 75 wt % of a bisphenol F epoxy resin, 6 wt % of a hardener (maleic anhydride), and 5 wt % of a solvent (butyl carbitol acetate).
[0056] As a result, in comparison with the cases of Comparative Example 1 (a conventional conductive adhesive), Comparative Example 5 (a silane coupling agent was added), and Comparative Example 7 (an epoxy resin into which a phosphoric ester group was introduced), the amount of deflection at the time of NG rose, and the adhesive strength against the bending stress improved.
EXAMPLE 2
[0057] The binder resin used for the conductive adhesive was the same epoxy resin as in Example 1 in which a dicarbonyl group was bonded to its side chain (chemical formula 4 above). A conventional Cu thick foil was used as the electrode.
[0058] As a result, in comparison with the cases of Comparative Example 2 (a conventional conductive adhesive), Comparative Example 6 (a silane coupling agent was added), and Comparative Example 8 (an epoxy resin into which a phosphoric ester group was introduced), the amount of deflection at the time of NG rose, and the adhesive strength against the bending stress improved.
EXAMPLE 3
[0059] Except that a thermoplastic silicone resin was used in which a dicarbonyl group was introduced into the side chain of silicone expressed by the chemical formula 5 below, the constitutions were the same as in Example 1.
[0060] As a result, in comparison with the cases of Comparative Example 1 (a conventional conductive adhesive), Comparative Example 5 (a silane coupling agent was added), and Comparative Example 7 (an epoxy resin into which a phosphoric ester group was introduced), the amount of deflection at the time of NG rose, and the adhesive strength against the bending stress improved.
EXAMPLE 4
[0061] The binder resin used for the conductive adhesive was the resin in which a dicarbonyl group was bonded to the side chain of a silicone resin expressed by the chemical formula 4 above. A conventional Cu foil was used as the electrode.
[0062] As a result, in comparison with the cases of Comparative Example 2 (a conventional conductive adhesive), Comparative Example 6 (a silane coupling agent was added), and Comparative Example 8 (an epoxy resin into which a phosphoric ester group was introduced), the amount of deflection at the time of NG rose, and the adhesive strength against the bending stress improved. Furthermore, the adhesive strength was higher than in Example 2.
EXAMPLE 5
[0063] Except that an epoxy resin was used in which the ligand to be introduced into the resin was changed to an aminocarbonyl group in Example 1 expressed by the chemical formula 6 below, the constitutions were the same as in Example 1.
[0064] As a result, in comparison with the cases of Comparative Example 1 (a conventional conductive adhesive), Comparative Example 5 (a silane coupling agent was added), and Comparative Example 7 (an epoxy resin into which a phosphoric ester group was introduced), the amount of deflection at the time of NG rose, and the adhesive strength against the bending stress improved.
EXAMPLE 6
[0065] Except that the electrode was changed to a calcined Cu thick foil, the constitutions were the same as in Example 5.
[0066] As a result, in comparison with the cases of Comparative Example 2 (a conventional conductive adhesive), Comparative Example 6 (a silane coupling agent was added), and Comparative Example 8 (an epoxy resin into which a phosphoric ester group was introduced), the amount of deflection at the time of NG rose, and the adhesive strength against the bending stress improved.
EXAMPLE 7
[0067] Except that an epoxy resin was used in which the ligand to be introduced into the resin was changed to a dicarbonyl group in Example 1 expressed by the chemical formula 7 below, the constitutions were the same as in Example 1.
[0068] As a result, in comparison with the cases of Comparative Example 1 (a conventional conductive adhesive), Comparative Example 5 (a silane coupling agent was added), and Comparative Example 7 (an epoxy resin into which a phosphoric ester group was introduced), the amount of deflection at the time of NG rose, and the adhesive strength against the bending stress improved.
EXAMPLE 8
[0069] Except that the electrode was changed to a calcined Cu thick foil, the constitutions were the same as in Example 7.
[0070] As a result, in comparison with the cases of Comparative Example 2 (a conventional conductive adhesive), Comparative Example 6 (a silane coupling agent was added), and Comparative Example 8 (an epoxy resin into which a phosphoric ester group was introduced), the amount of deflection at the time of NG rose, and the adhesive strength against the bending stress improved.
EXAMPLE 9
[0071] Except that an epoxy resin was used in which the ligand to be introduced into the resin was changed to a dicarbonyl group expressed by the chemical formula 8 below, the constitutions were the same as in Example 1.
[0072] As a result, in comparison with the cases of Comparative Example 1 (a conventional conductive adhesive), Comparative Example 5 (a silane coupling agent was added), and Comparative Example 7 (an epoxy resin into which a phosphoric ester group was introduced), the amount of deflection at the time of NG rose, and the adhesive strength against the bending stress improved.
EXAMPLE 10
[0073] Except that the electrode was changed to a calcined Cu thick foil, the constitutions were the same as in Example 9.
[0074] As a result, in comparison with the cases of Comparative Example 2 (a conventional conductive adhesive), Comparative Example 6 (a silane coupling agent was added), and Comparative Example 8 (an epoxy resin into which a phosphoric ester group was introduced), the amount of deflection at the time of NG rose, and the adhesive strength against the bending stress improved.
EXAMPLE 11
[0075] Except that an epoxy resin was used in which the ligand to be introduced into the resin was changed to a dicarbonyl group expressed by the chemical formula 9 below, the constitutions were the same as in Example 1.
[0076] As a result, in comparison with the cases of Comparative Example 1 (a conventional conductive adhesive), Comparative Example 5 (a silane coupling agent was added), and Comparative Example 7 (an epoxy resin into which a phosphoric ester group was introduced), the amount of deflection at the time of NG rose, and the adhesive strength against the bending stress improved.
EXAMPLE 12
[0077] Except that the electrode was changed to a calcined Cu thick foil, the constitutions were the same as in Example 11.
[0078] As a result, in comparison with the cases of Comparative Example 2 (a conventional conductive adhesive), Comparative Example 6 (a silane coupling agent was added), and Comparative Example 8 (an epoxy resin into which a phosphoric ester group was introduced), the amount of deflection at the time of NG rose, and the adhesive strength against the bending stress improved.
EXAMPLE 13
[0079] Except that an epoxy resin was used in which the ligand to be introduced into the resin was changed to a dicarbonyl group expressed by the chemical formula 10 below (where n indicates a degree of polymerization of about 2 in average), the constitutions were the same as in Example 1.
[0080] As a result, in comparison with the cases of Comparative Example 1 (a conventional conductive adhesive), Comparative Example 5 (a silane coupling agent was added), and Comparative Example 7 (an epoxy resin into which a phosphoric ester group was introduced), the amount of deflection at the time of NG rose, and the adhesive strength against the bending stress improved.
EXAMPLE 14
[0081] Except that the electrode was changed to a calcined Cu thick foil, the constitutions were the same as in Example 13.
[0082] As a result, in comparison with the cases of Comparative Example 2 (a conventional conductive adhesive), Comparative Example 6 (a silane coupling agent was added), and Comparative Example 8 (an epoxy resin into which a phosphoric ester group was introduced), the amount of deflection at the time of NG rose, and the adhesive strength against the bending stress improved.
COMPARATIVE EXAMPLE 1
[0083] Except that a conventional conductive adhesive of the following composition was used in place of the binder resin in Example 1, the experiment was performed in the same manner as in Example 1.
bisphenol F-type epoxy resin 90 wt % hardener (diethylenetriamine) 5 wt % solvent (butyl carbitol acetate) 5 wt %
COMPARATIVE EXAMPLE 2
[0084] Except that a calcined Cu thick foil was used in place of the Cu foil in Comparative Example 1, the experiment was performed in the same manner as in Comparative Example 1.
COMPARATIVE EXAMPLE 3
[0085] Except that a both-end hydrogen-dimethyl disilicone resin was used in place of the binder resin in Example 3, the experiment was performed in the same manner as in Example 1.
COMPARATIVE EXAMPLE 4
[0086] Except that a calcined Cu thick foil was used in place of the Cu foil in Comparative Example 3, the experiment was performed in the same manner as in Comparative Example 3.
COMPARATIVE EXAMPLE 5
[0087] Except that a silane coupling agent was used in place of the binder resin in Example 1, the experiment was performed in the same manner as in Example 1.
COMPARATIVE EXAMPLE 6
[0088] Except that a calcined Cu thick foil was used in place of the Cu foil in Comparative Example 5, the experiment was performed in the same manner as in Comparative Example 5.
COMPARATIVE EXAMPLE 7
[0089] Except that an epoxy resin in which a phosphoric ester group was introduced into its molecular skeleton was used in place of the binder resin in Example 1, the experiment was performed in the same manner as in Example 1.
COMPARATIVE EXAMPLE 8
[0090] Except that a calcined Cu thick foil was used in place of the Cu foil in Comparative Example 7, the experiment was performed in the same manner as in Comparative Example 7.
[0091] All the results of Examples 1 to 14 and Comparative Examples 1 to 8 above of the present invention are shown in Table 1 below.
Table 1-1 Conductive Adhesive Rate of Content Experi- Binder Resin (in total mental Resin introduced with ligand resin) Conductive No. Skeleton Ligand (wt %) particle Example 1 epoxy dicarbonyl group 15 Ag Example 2 epoxy dicarbonyl group 15 Ag Example 3 silicone dicarbonyl group 15 Ag Example 4 silicone dicarbonyl group 15 Ag Example 5 epoxy aminocarbon-yl group 15 Ag Example 6 epoxy aminocarbon-yl group 15 Ag Example 7 epoxy dicarbonyl group 15 Ag Example 8 epoxy dicarbonyl group 15 Ag Example 9 epoxy dicarbonyl group 15 Ag Example 10 epoxy dicarbonyl group 15 Ag Example 11 epoxy dicarbonyl group 65 Ag Example 12 epoxy dicarbonyl group 65 Ag Example 13 epoxy dicarbonyl group 65 Ag Example 14 epoxy dicarbonyl group 65 Ag Compar. epoxy none 0 Ag Example 1 Compar. epoxy none 0 Ag Example 2 Compar. silicone none 0 Ag Example 3 Compar. silicone none 0 Ag Example 4 Compar. epoxy none (silane 0 Ag Example 5 coupling agent added) Compar. epoxy none (silane 0 Ag Example 6 coupling agent added) Compar. epoxy a phosphoric ester 15 Ag Example 7 group Compar. epoxy a phosphoric ester 15 Ag Example 8 group
[0092] In the Examples of the present invention above, the binder resins used for the conductive adhesive were only an epoxy resin and a silicone resin, but other resins described in the Embodiments also are effective for use. Moreover, only a dicarbonyl group was shown as the ligand bonded to the side chain of the binder resin, but other ligands described in the Embodiments also may be used. Furthermore, only copper was used as the electrode metal, but other metals generally used for electrodes as described in the Embodiments also may be used.
[0093] According to the present invention, the problems with regard to the mounting of conductive adhesives, i.e. the adhesive strength and particularly the strength against the bending stress, can be solved easily. The present invention greatly contributes to the commercial application of the mounting technique using conductive adhesives.
[0094] The invention may be embodied in other 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 limiting. The scope of the invention is indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are intended to be embraced therein.
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A mounting technique with improved adhesive strength and higher reliability against bending stress is provided with the use of a conductive adhesive including a binder resin and a metal filler as main components, in which a functional group is introduced into the molecular chain of the binder resin to form a multidentate bonding with an electrode metal easily. As a thermoplastic resin, at least two kinds of functional groups selected from the group consisting of a carbonyl group, a carboxyl group, an amino group, an imino group, an iminoacetic acid group, an iminopropionic acid group, a hydroxyl group, a thiol group, a pyridinium group, an imido group, an azo group, a nitrilo group, an ammonium group and an imidazole group are introduced. Accordingly, a strong bond with the electrode metal can be achieved. The conductive adhesive is screen-printed to an electrode disposed on a substrate, and after an electrode of a component is mounted, the structure is heated so as to create a mounted structure.
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PRIORITY CLAIM
[0001] This application claims priority to corresponding U.S. Provisional Application No. 61/001,055, filed on Oct. 31, 2007, the disclosure and contents of which are expressly incorporated herein by reference.
FIELD OF INVENTION
[0002] The present invention relates to a fender system that can be applied to a dock piling in order to prevent damage to a vessel whereby the fender uniquely rises and falls with the tide such that the fender is always in the most suitable position for protecting the vessel.
BACKGROUND OF THE INVENTION
[0003] With respect to commercial and recreational marine vessels, the vessels are regularly kept within a marina, harbor or port for a period of time while not being used alongside a dock area with a number of vertical dock pilings. Typically, the vessel is somehow attached or otherwise confined to the dock in order that the current and tide does not cause the vessel to stray from the dock area. As a result, the hull, transom or gunwale of the vessel routinely encounters the dock or dock piling each time the vessel pitches and rolls against the dock area due to the underlying current and rise and fall of the tide. Furthermore, in some instances, the vessel may even work itself under the dock if there is no structural barrier between the vessel and the dock. Therefore, a number of systems have been developed in order to protect the vessel's structure from being damaged by the dock pilings.
[0004] For example, bumpers have been applied to the vessel's railings and alongside the dock pilings themselves. The bumpers are typically made with rubber pads or strips. Unfortunately, the pads or strips are usually only capable of handling any rubbing engagement that occurs between a vessel and a piling, and cannot withstand the full force of an impact between the vessel and the dock piling. During a forceful impact, the pads or strips either do not have enough cushion to prevent any damage or are ripped away from their fastened position on the underlying vessel or piling structure rendering the bumpers ineffective and causing structural damage to the vessel or piling. In addition, the bumpers are unsightly when applied to a vessel or a piling thereby ruining the aesthetic appeal of the vessel or dock area. Packaging, cushions, carpeting and even corrugated cardboard have also been strapped to dock pilings with duct tape in an attempt to provide protection to the vessel. However, these solutions are only temporary as they degrade easily and quickly become unsightly.
[0005] In another example, fenders have been developed for mounting to and hanging over the waterside edge of the stem, fantail or gunwale of the vessel such that the fender acts as a physical buffer that prevents the vessel from coming into direct contact with the dock piling. A typical fender is in the form of a cylindrical, elongated tube, rounded at both ends or formed similar to a barrel, and is completely or partially filled with air, water or a cellular foam core to cushion and absorb the shock of the vessel bumping and banging against the dock piling. The fender typically has a line, such as a nylon cord or rope, at its upper end that is somehow attached or tied to the vessel. The fender simply hangs down from the gunwale to protect the sides of the vessel. However, in order to be effective, the fender must be suspended from the vessel at a precise length in order to be positioned such that the dock piling hits the vessel at the section that comes in contact with the fender. Therefore, the fender cannot just rely upon its buoyancy for placing it in the right place as the water level may not be where the vessel contacts with the dock. Determining the precise length of the fender is not a simple task and requires some trial and error, particularly when the level of the water is constantly rising and falling. Furthermore, because the fender is suspended from its top but is free-floating at its bottom such that there is little tension in the line, the fender can easily be errantly moved out of position and relies upon the vessel compressing the fender in place against the dock in order to keep it in position. Thus, a fender suspended from the vessel is completely useless in storm conditions. In some instances, the fender contains water or another substance that adds weight to the fender while still remaining buoyant. However, the inconvenience associated with locating the fender at a precise location under changing conditions still exists. In addition, although fenders are easily portable, the fender must be transported with the vessel during its entire voyage as unused cargo.
[0006] Therefore, there exists a need for a system of sufficient strength and cushion to absorb the full force impact between a vessel and a dock piling that is not difficult to correctly position and is permanently attached to the vessel or piling such that it cannot be easily moved out of the correct position.
[0007] In order to reduce the difficulty in attaching a suitable buffer to a vessel in the appropriate location and the undesirable added weight of applying a buffer to the vessel, systems have been developed for securing an existing inflatable fender or some other type of mooring device to a dock or pier rather than applying the fender or other device to the vessel. As a result, there is flexibility in receiving the impact of the vessel without the displacement of the fender or other device from its secured position.
[0008] For example, one system is comprised of an inflatable fender that is attached to a boat docking structure using at least two brackets that are secured to the boat docking structure on each side of the fender using screws. A strap is adjustably received by the two brackets and completely encircles the fender thereby securing the fender to the boat docking structure. In addition, the fender can have a center opening for running a line longitudinally through the fender whereby the line is attached to the boat docking structure using a hook or eyebolt to assist in securing the fender to the boat docking structure. Thus, upon impact of the boat with the fender, the fender cannot move relative to the boat docking structure. A series of these fenders can be applied vertically and/or horizontally in a linear fashion along the boat docking structure in order to cover the entire length wherein a vessel may come in contact with the boat docking structure.
[0009] In another example, rather than using readily available and conventional inflated fenders, one system employs a device having an extension arm that is attached to a dock in a fixed position. The extension arm is connected to one or more spring-loaded solid or air-filled rollers or wheels. The extension arm of the device is spaced from the dock in a manner so as to stand off a floating vessel using the solid or air-filled rollers while the vessel is tied to a stationary dock or piling. The spring-loaded rollers rotate against the vessel in order to allow the vessel to move with the vertical tide action, current and light wave or wave motion.
[0010] However, although these devices are attached permanently to the dock pilings such that the dock piling can receive the impact of the vessel without the displacement of the fender or other device from its secured position, none of these devices are capable of automatically changing position in response to the rise and fall of the water level. Therefore, these devices are not suitable for use in waters in which the water level is constantly changing. In order to protect the dock, a number of the fenders or other devices have to be installed up and down the dock area in series, which is highly unattractive particularly in recreational marinas. Furthermore, some of the fenders or other devices may need to be installed in places that, for a portion of the time, are under the water line in order to be prepared for events in which the water level drops significantly. This exposes the fenders or other devices and their means of attachment to the dock area to corrosion and to the growth of bacteria, barnacles and other damaging marine life. Accordingly, there exists a need for a fender-like system that is permanently attached to the dock side in order to maintain position and is capable of automatically adjusting in response to the rise and fall of the water level caused by the underlying current.
[0011] Devices with this automatic adjustment feature have been developed for mooring or otherwise confining a marine vessel to a dock area. For example, a self adjusting tidal mooring device has been developed for mounting onto mooring poles or pilings. The device includes one or more stainless steel vertical slide shafts that are mounted along the vertical length of the sides of the mooring pole or piling using stainless steel mounting plates. A polyethylene sliding block is affixed to the slide shaft such that it can be slide up and down the slide shaft. One end of a rope is secured to the sliding block while the other end of the rope is tied to the watercraft's cleats. The weight of the vertical slide block keeps tension on the rope. As the water level rises and falls, the sliding block moves up and down the vertical slide shaft allowing the watercraft to move vertically in the mooring slip but still remain securely positioned in relation to the dock.
[0012] In another example, a boat mooring apparatus, which has been developed for securing a boat to a vertical piling, includes a vertical elongated member that is mounted to the piling and has a longitudinal track along its length. A carriage is mounted such that it may slide within the track. A float support is secured to the carriage exterior at its upper end and is connected to a float on its lower end. The float is typically an air-filled cylinder that has sufficient buoyancy to float its own mass as well as that of the float support and the carriage. The float support transmits the tide forces acting on the float to the carriage in order to adjust the position of the carriage in response to changes in the tide. A line of suitable length and thickness for the boat to be moored is attached to a ring connected to the float support and is extended to moor the boat. As a result, the boat floats up and down with the float support and the strain on the mooring lines remains the same at all times.
[0013] However, none of these devices are capable of acting as a buffer between the vessel and the dock area because they do not provide an offset from the dock. These devices only operate to keep the vessel proximate to the dock area such that the vessel does not dangerously stray from the area.
[0014] Several systems exist for adjusting the length of the lines which suspend the fenders from either a source on the dock side or on the vessel side of the system in relation to the changes in tide. For example, a crane or derrick with suspended cables that are attached to a weighted fender can be used to manually hoist or lower the fender when desired. However, unlike the mooring devices describe above, each of these systems is not automatically responsive to the actual rise and fall of the water level as they require manual intervention in order to move the fender. Thus, there still exists a need for a fender-like system that is permanently attached to the dock side and is capable of automatically adjusting in response to the rise and fall of the water level and the underlying current.
SUMMARY OF THE INVENTION
[0015] The present invention provides a fender system that is applied to a dock piling in order to prevent damage to a marine vessel while the vessel is moored to a fixed or floating dock or dock piling. The fender is designed to uniquely rise and fall with the level of the tide such that the fender is always in the most suitable position for protecting the vessel's hull from coming into direct contact with the piling. Thus, this system is useful in waters in which there is a constant ebb and flow of the tide and is especially useful in areas experiencing a storm surge.
[0016] The present invention is affixed to a vertical dock piling or solid faced pier and is designed to allow the fender to rise and fall automatically with the tide all the way up to the top of the piling or solid face of pier in the event of a storm surge and all the way down to the lowest water point at the lowest tide. The fender not only rises and falls with the tide, but also stays in the proper location against the piling and the vessel's rub rail in order to be an effective fender at all stages of the tide. The present invention helps protect a vessel's hull from coming into direct contact with a piling at even the most extreme tides, thus reducing the chance of damaging the vessel or dock.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a side view of a preferred embodiment of the fender system of the present invention depicted as being mounted to a vertical dock piling at low tide.
[0018] FIG. 2 is side view of a first alternative embodiment of the fender system of the present invention depicted as being mounted to a vertical dock piling.
[0019] FIG. 3 is a side view of a second alternative embodiment of the fender system of the present invention depicted as being mounted to a vertical dock piling.
[0020] FIG. 4 is a side view of a second preferred embodiment of the fender system of the present invention depicted as being mounted to a vertical dock piling.
[0021] FIG. 5 is a perspective view of the bracket of FIG. 1 as attached to a cable.
[0022] FIG. 6 is a side view of the embodiment of FIG. 1 depicted as being mounted to a vertical dock piling at high tide.
DETAILED DESCRIPTION OF THE INVENTION
[0023] For a better understanding of the present invention, reference may be made to the following detailed description taken in conjunction with the appended claims and the accompanying drawings.
[0024] Referring to FIG. 1 , the fender system 1 of the present invention is generally comprised of a bracket 2 that is affixed to a vertical dock piling 3 , a mechanical means 4 that attaches a cable 5 to the bracket 2 , a fender 6 with a vertical hole 7 for passage of the cable 5 there through, a pipe 8 just below the fender 6 having a vertical hole 9 for passage of the cable 5 there through, a float 10 for providing the buoyancy for the fender 6 and having a vertical hole 11 for passage of the cable 5 , and a weight 12 that is attached to the terminating end of the cable 5 .
[0025] In a preferred embodiment, the fender system 1 includes a bracket 2 that is attached at one end to a vertical dock piling 3 near the top 13 of the dock piling in order for the fender system 1 to operate along the entire length of the dock piling. The fender system of the present invention is designed to allow the fender to rise and fall automatically with the tide all the way to the top of the piling in the event of a storm or a hurricane. FIG. 1 depicts the present invention being used during a low tide condition. FIG. 6 depicts the embodiment of FIG. 1 being used during a high tide condition wherein the fender has risen to near the top of the piling and closer to the bracket 2 . Preferably, the bracket 2 is a flat bar that is composed of aluminum or stainless steel that has been bent into a 180° degree arc 14 in a bowed configuration that is curved downwards with respect to the water line 40 . The arc 14 prevents the bracket from harmfully puncturing a vessel should it somehow come into contact with the vessel. Also, by bending the bracket into an arc, the mechanical stresses placed upon the bracket are more evenly distributed along the entire length of the bracket rather than loading the stresses at the point where the bracket is attached to the piling. In addition, the arced bracket can more easily adapt to forces resulting from high winds and tumultuous water conditions. The end of the bracket 2 is preferably affixed directly to the dock piling 3 with two lag screws 15 that are threaded through two ¼″ inch holes 16 .
[0026] As shown in detail in FIG. 5 , at the protruding end of the bracket 2 is a ½″ inch hole 17 through which a sleeve 4 passes through the bracket 2 . This sleeve is preferably made of a non-corroding material, such as nylon, and is used to prevent corrosion between the metal bracket 2 and the metal shackle 19 that is further described below. A cable 5 is attached to the bracket 2 using the shackle 19 and a thimble 20 , whereby the shackle 19 is passed through the sleeve 4 and its bottom is passed through the thimble 20 . Preferably, the cable 5 , shackle 19 and thimble 20 are each composed of stainless steel metal. The thimble 20 is thereafter attached to a ¼″ inch stainless steel cable 5 by a swage fitting 22 . Thus, the cable 5 is provided with a wide range of movement at the bracket 2 by the shackle 19 .
[0027] The cable 5 is inserted into and through a fender 6 whereby the fender 6 has a vertical hole 7 that runs longitudinally through its center such that the fender can slide freely up and down the length of the cable 5 . The fender can be any appropriate shape for the vessel it is protecting and made from any material which provides suitable impact cushioning between a vessel and the structure to which it is moored. In a most preferred embodiment, the fender is cylindrical in shape and made from a closed cell polystyrene or vinyl, in which case the vinyl is inflated for the cushioning affect and has a hole running longitudinally through the fender.
[0028] Just below the fender 6 , a hollow pipe 8 may be used in order to vary the height of the fender 6 . The pipe 8 has a vertical hole 9 through its center in order for the cable 5 to be inserted through the hole 9 . Preferably, the pipe 8 is made of polyvinyl chloride (PVC) and has a longitudinal slit the length of the pipe in order for the cable to be passed through. The slit would be sized to permit the pipe to fit over the cable. For example, where a ¼″ inch cable is chosen, the slit would be approximately ¼″ inches. The length of the pipe 8 is preferably dependent upon the height of the vessel's gunwale. The pipe should be sized such that the middle of the fender is positioned at the gunwale of the vessel. Furthermore, PVC end caps 27 and 28 may be placed at both ends of the pipe with a hole in the middle of the cap for the cable to pass through 8 . Alternatively, the end caps may be notched to allow passage over the cable. Below the pipe 8 is a float 10 that is composed of any suitable buoyant material and has a vertical hole 11 through which the cable 5 passes through. While the float can be made from any suitable non-marring buoyant material, the float 10 is preferably composed of a foam or plastic. In a preferred embodiment, the float is made out of polystyrene, closed cell foam, or Styrofoam and has the shape of a bullet in which there is a hole for the cable to pass through. The float provides the buoyancy for the fender 6 and prevents the fender 6 from coming into contact with the water line 40 . A weight 12 is attached to the terminating end of the cable 5 in order to provide tension in the cable 5 and to keep the entire fender system 1 in vertical alignment along the dock piling 3 . The weight 12 will maintain the positioning of the fender 6 in the presence of a strong underlying current that would typically drag the fender out of position. While any material of suitable mass and dimensions can be used, in one embodiment, the weight is a metal anchor that is attached to the cable 5 using a stainless steel wire clamp 29 and thimble 30 . The overall length of the cable 5 is dependent on the depth of the water as well as the desired location of the weight 12 . Preferably, the weight 12 is located 1 ′ foot off the sea floor 18 . It is understood that the term sea floor means the bottom of the waterway in which the dock or pier rests.
[0029] In an alternative embodiment, as shown in FIG. 2 , the fender system 1 does not include a sleeve. Rather, the shackle 19 is connected to the protruding end of the bracket 2 using an eye bolt 32 that passes through the hole 17 and is secured to the bracket 2 by one or more washers 31 and one or more nuts 33 on either side of the bracket 2 .
[0030] In another alternative embodiment, as shown in FIG. 3 , the fender system 1 could employ two or more stainless steel flat bar brackets (e.g. 34 and 35 ), bent at a 90° degree angle, for attaching the fender 6 and a stainless steel rod or cable 38 to the piling 3 . Preferably, one bracket is mounted at the top of the piling 3 and a second bracket is mounted below the low water mark 39 . Each 90° degree bracket has two holes 16 and 36 for the lag screws 15 to secure the brackets to the piling 3 . In addition, each bracket has a hole 37 to allow a stainless steel rod or cable 38 to pass through. The stainless steel rod or cable 38 passes through the holes in the horizontal portion of the upper and lower brackets 34 and 35 . The rod or cable 38 is connected to the upper and lower brackets via a hole 40 drilled through the rod or cable 38 and a stainless steel screw and nut 41 are placed on the outermost ends of the rod or cable 38 . A fender 6 with a vertical hole 7 through its middle slides vertically up and down the rod or cable 38 . Below the fender 6 is a buoyant float 10 with a vertical hole 11 through the middle wherein the rod or cable 38 passes through the hole 11 . The float 10 keeps the fender 6 out of the water. Accordingly, due to the float 10 , the fender 6 automatically rises and falls with the tide and prevents the manual adjustment of the fender to keep the fender at the correct height. By attaching the rod or cable 38 to both the top and bottom brackets, the fender system 1 has a suitable strength for enduring severe storm and water conditions.
[0031] In a second preferred embodiment, as shown in FIG. 4 , the bracket 2 of the fender system 1 is identical to the fender system described above and shown in FIG. 1 except that the terminating end of the cable 5 is not attached to a weight 12 . Rather, a 90° degree bracket 42 is mounted to the piling 3 below the low water mark 39 . The terminating end of cable 5 is attached to a hole 45 in the 90° degree bracket 42 using one or more stainless steel U-clamps 43 and a stainless steel shackle 44 . Thus, the bottom bracket 42 provides strength and stabilization to the fender system 1 of FIG. 1 .
[0032] All materials used in the construction of the present device should be selected for their ability to survive in a wet and/or salty environment. Materials that touch should be made from galvanically acceptable materials or should be made from non-corroding materials such as nylon. The term “galvanically acceptable” should be construed to mean that two or more different materials, when in contact, will not create unacceptable galvanic currents which lead to erosion of one or more of the materials. Such materials are known in the marine industry. Stainless steels such as type 316 are among the preferred galvanically acceptable materials. In instances where galvanically acceptable materials cannot be chosen, the present invention may need to be protected by the use of sacrificial anodes such as zinc, aluminum or magnesium as are known in the art.
[0033] In the foregoing description, the present invention has been described with reference to specific exemplary embodiments thereof. It will be apparent to those skilled in the art that a person understanding this invention may conceive of changes or other embodiments or variations, which utilize the principles of this invention without departing from the broader spirit and scope of the invention. The specification and drawings are, therefore, to be regarded in an illustrative rather than a restrictive sense. Accordingly, it is not intended that the invention be limited except as may be necessary in view of the appended claims.
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The present invention provides a fender system that is applied to a dock piling or solid faced bulkhead in order to prevent damage to a marine vessel while the vessel is moored to a fixed or floating dock, or dock piling, or solid faced bulkhead. The fender is designed to uniquely rise and fall with the level of the tide such that the fender is always in the most suitable position for protecting the vessel's hull from coming into direct contact with the piling or bulkhead. Thus, this system is useful in waters in which there is a constant ebb and flow of the tide and is especially useful in areas experiencing a storm surge.
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[0001] PRIORITY/CROSS-REFERENCE TO RELATED APPLICATIONS
[0002] This application is a continuation in part of U.S. Nonprovisional Application No. 15/285,954 filed Oct. 5, 2016 which is a continuation of U.S. Nonprovisional Application No. 14/529,439 filed Oct. 31, 2014 which claims the benefit of U.S. Provisional Application No. 61926689, filed Jan. 13, 2014, the disclosures of which are incorporated by reference.
TECHNICAL FIELD
[0003] The presently disclosed and claimed technology generally relates to an apparatus for fluid and/or gas flow control by a new control valve.
BACKGROUND
[0004] Valves regulate, control, and direct the flow of fluids and/or gas that come from one source to another source. A valve is an apparatus that is used to the change the direction and flow of moving fluid and/or gases. Valves can be used to raise and lower pressure of fluids and/or gases flowing in a direction. Additionally, valves have been used to obstruct fluids and/or gases flowing in one direction, while redirecting it in another direction.
[0005] Valves have a multitude of uses, such as in the irrigation industry, residential and commercial property industry, and automobile industry, among a plethora of other industries. Valves have penetrated society because of their usefulness. Safety valves, pressure valves, temperature valves, hydraulic valves, pneumatic valves, solenoid valves, and piston valves are example of types of valves.
[0006] Valves have a categorically broad field of form and application varying in size, and type. Valves are used in moving fluids and/or gases.
[0007] Many valves comprise of ports and passage ways which are passages that fluids and/or gases pass through. Ports can be obstructed when in use which is the function of a properly functioning valve. The obstruction of ports controls the flow of the fluids and/or gas. Most valves contain two or more controlled by a disc or ball that is actuated by a mechanism, sensor, or manually. Some valves are actuated automatically.
[0008] Ball valves are a form of valve which has two configurations: open and closed. When open, a ball valve allows fluid and/or gas to flow through a hollowed center of a ball or spherical flow control using an actuator to rotate the valve to align passageways through the valve with openings in the housing of the valve. For example when closed, the hollowed passageway of one type of ball valve is perpendicular to the incoming fluid and/or gas which prohibits the flow of fluid and/or gas. Ball valves can be metal, plastic, ceramic, or some other useful material.
DEFINITIONS
[0009] The use of the phrase “in the alternative,” “other sources,” “different sources,” “e.g.,” “etc,” and “or” indicates non-exclusive alternatives without limitation unless otherwise noted.
[0010] The use of the phrases “fluid”, “gas” or “fluid and/or gas” relates to all categories of fluids, liquids, solids turned liquid, and all categories of gases, vapors, melts, and condensations.
SUMMARY OF DISCLOSURE
[0011] The purpose of the Summary of Disclosure is to enable the public, 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 Summary of the Invention 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.
[0012] What is disclosed is a valve. This valve can be configured to for the flow of fluid and/or gas through several passageways and ports in a preferred embodiment. There are different configurations: a first position, and a second position, etc. Each position is unique and allows for different sources of fluid and/or gas to flow through different ports. The valve is a ball valve in some embodiments.
[0013] When connected to an external hose, pipe, or other sources, the first inlet port allows for the flow of fluid and/or gas to the inner part of the valve. When the fluid and/or gas reach the inner part of the valve it will travel through a spherical flow control (or “ball”) within the valve housing. Depending on what position the valve is in, the fluid and/or gases will be directed either from the first inlet port to the first outlet port; or the first inlet port to the second outlet port and the second inlet port to the first outlet port.
[0014] In the first position, the fluid and/or gas will pass from the first inlet port through the first inner passage way and out of the first outlet port. In a preferred embodiment, in the first position, the only passage of fluid and/or gas is from the first inlet port to the first outlet port and the other passage ways and ports are not utilized.
[0015] In the second position, fluid and/or gas will enter through the first inlet port and travel though the outer passage way of the valve which will direct the flow of fluid and/or gas to the second outlet port. Fluid and/or gas flows through the second inlet port and pass through the ball valve through the second inner passage way to the first outlet port.
[0016] An actuator, such as a handle, solenoid, or other actuator, selectively determines the position of the valve. In a preferred embodiment, the actuator sits adjacent to the first chamber of the valve. In a preferred embodiment in which the actuator is a handle, the handle is connected to the ball valve using a handle coupling mechanism which is coupled to a shaft attached to the ball valve. The handle is rotated to change the position of the ball valve in a preferred embodiment. When the handle is turned in one direction, the ball valve is configured to be in the first position. When the handle is rotated in another direction from the first position, the valve is configured to be in the second position. A handle stop can be utilized to ensure the ball valve is in the correct orientation of first position or second position.
[0017] In the preferred embodiment, the ball valve has different passageways: the first inner passageway, the second inner passageway, an outer passageway, or other alternative passage ways. The first inner passageway of the ball valve is located on the circumference of the ball valve or another alternative. The second inner passageway generally is perpendicular to the first inner passageway or another alternative. The second inner passageway provides a passage way in the circumference of the ball valve and intersects with the first inner passageway, or another alternative. Fluid and/or gas flows through the first inner passageway and through the second inner passageway depending on which position the handle is positioned. If the handle is in the first positon, fluid and/or gas will travel from the first inlet port to the first outlet port. If the handle is in the second position, fluid and/or gas will travel from the first inlet port to the second outlet port and from the second inlet port to the first outlet port. When the ball valve is in the first position, and fluid and/or gas flows through the first inlet port through the first passageway and out the first outlet port of the valve. Fluid and/or gas do not flow through the second passageway because the second passageway is blocked by the inside of the housing of the first chamber. Fluid and/or gas will not flow through the outer passage way when the valve is in the first position because the outer passage way will be blocked.
[0018] In a preferred embodiment, when the valve is in the second position the second inner passage way and the outer passage way of the ball valve are configured to be in an engaged position. When in this configuration, fluid and/or gas will flow through the first inlet port to the ball valve then though the outer passage way. Fluid and/or gas can then flow through the outer passage way to the second outlet port. Fluid and/or gas can flow from the second inlet port to the ball valve through the second inner passage way and to the first outlet port.
[0019] In further embodiment, the second outlet port is in a second chamber. In a preferred embodiment, there are two chambers to the valve. The first chamber has a first inlet port, first outlet port, and a second inner port. The second chamber has a second outlet port. In the first position, the second chamber is blocked from receiving fluid and/or gas from the first chamber. In the second position, fluid and/or gas will come through the first inlet port in the first chamber, and out of the second outlet port in the second chamber.
[0020] In a preferred embodiment, the valve is made of brass or an alternative material including but not limited to other metals, and plastics. The valve can be configured to allow for the connection of different types and sizes of hoses, pipes, or other sources.
[0021] In a preferred embodiment, the first inlet port and the first outlet port are threaded female ports. In a preferred embodiment, the second inlet port and the second outlet port are threaded male connections. However, any configuration from alternative sources using alternative connections such as quick connects, hose clamps, or other connection can be used to connect fluid and/or gas lines.
[0022] The valve comprises one or more seals or gaskets that fill the space between the ball valve and the chamber. In the preferred embodiment, the valve comprises of one or more neoprene gaskets that encapsulate the ball valve and have openings corresponding with openings in the circumference of the ball or spherical control of the valve. These gaskets help form a seal to prevent leakage of fluid and/or gas from penetrating to a passage not meant to be utilized. The seals can vary in shape, material, and dimensions.
[0023] Still other features and advantages of the claimed invention will become readily apparent to those skilled in this art from the following detailed description describing preferred embodiments of the invention, simply by way of illustration of the best mode contemplated by carrying out my invention. As will be realized, the invention is capable of modification in various obvious respects all without departing from the invention. Accordingly, the description of the preferred embodiments is to be regarded as illustrative in nature, and not as restrictive in nature.
BRIEF DESCRIPTION OF DRAWINGS
[0024] FIG. 1 is a front right perspective view of a preferred embodiment of a valve.
[0025] FIG. 2 is a front side view of a preferred embodiment of a valve.
[0026] FIG. 3 is a right side view of a preferred embodiment of a valve.
[0027] FIG. 4 is an internal right view of a preferred embodiment of a valve.
[0028] FIG. 5 is an internal front view of a preferred embodiment of a valve.
[0029] FIG. 6 is an internal front right perspective view of the inner workings with the outer casing removed in a preferred embodiment of a valve in a first position.
[0030] FIG. 7 is an internal front right perspective view of the inner workings with the outer casing removed in a preferred embodiment of a valve in a second position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0031] While the presently disclosed inventive concept(s) is susceptible of various modifications and alternative constructions, certain illustrated embodiments thereof have been shown in the drawings and will be described below in detail. It should be understood, however, that there is no intention to limit the inventive concept(s) to the specific form disclosed, but, on the contrary, the presently disclosed and claimed inventive concept(s) is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the inventive concept(s) as defined in the claims.
[0032] Certain preferred embodiments of the disclosed technology are shown FIGS. 1 through 7 .
[0033] Disclosed in FIG. 1 is a diagram of a front right perspective view of the valve. The valve can be used with various forms of fluids and/or gases. The fluids and/or gases used with the valve can vary in temperature. FIG. 1 shows a first inlet port ( 2 ) and a first outlet port ( 4 ). When the handle ( 10 ) is in the first position ( 16 ) the valve allows for flow through the first inlet port ( 2 ), first inner passage way ( 24 ), and a first outlet port ( 4 ).
[0034] While in the first position ( 16 ), fluid and/or gas that pass through the first inlet port ( 2 ) is prevented from escaping through the second outlet port ( 8 ) due to the position of the ball valve ( 32 ). When the exchange value is in the first position ( 16 ), fluid and/or gas cannot pass through the second inner passage way ( 26 ) because it is open to the inside of the first chamber ( 12 ). The first position of the valve is set using the handle ( 10 ) which is coupled with the ball valve ( 32 ) using a handle coupling mechanism ( 18 ) that is connected to the ball valve shaft ( 10 ). FIG. 1 displays the second inlet port ( 6 ) and the second outlet port ( 8 ) that is in the second chamber ( 14 ) which are not utilized when the valve is in the first position ( 16 ).
[0035] As shown in FIG. 1 , the first chamber ( 12 ) of the valve comprises of the first inlet port ( 2 ), second inlet port ( 6 ), and the first outlet port ( 4 ).
[0036] FIG. 2 is a front view of the valve. As shown, the first inlet port ( 2 ) is on the right and the first outlet port ( 4 ) is on the left. The handle ( 10 ) is on the top of the valve. The first chamber ( 12 ) and the second chamber ( 14 ) are shown from the front view. In the center of the first chamber is the second inlet port ( 6 ). In the center of the first chamber is the second outlet port ( 8 ).
[0037] FIG. 3 is a right view of the valve. Shown is the handle ( 10 ) in the first position ( 16 ). The first chamber ( 12 ) sits on top of the second chamber ( 14 ). The second inlet port ( 6 ) and the second outlet port ( 8 ) are displayed as threaded male valves. These valves can connect to external hoses, piping, or other sources. The first inlet port ( 2 ) is a female threaded valve which can connect to an external hose, pipe, or other sources.
[0038] FIG. 4 is an internal right view of the valve. In this view, the handle ( 10 ) is in the first position ( 16 ). Shown is the handle coupling mechanism ( 18 ) which couples the handle to the ball valve shaft ( 20 ). The ball valve shaft ( 20 ) along with the handle ( 10 ) are used to rotate the ball valve ( 32 ) between the first position ( 16 ) and the exchange position ( 30 ). The ball valve shaft ( 20 ) and the ball valve ( 32 ) are in the first chamber ( 12 ). When in the first position ( 16 ) the first inner passage way ( 24 ) allows for fluid and/or gas to flow from the first inlet port ( 2 ) to the first outlet port ( 4 ). When in the first position ( 16 ), the second inner passage way ( 26 ) leads to the inside housing of the first chamber ( 12 ), disallowing the flow of fluid and/or gas through the second inner passage way ( 26 ). When the valve is in the first position ( 16 ), the outer passage way ( 22 ) of the ball valve ( 32 ) is rotated to the second inlet port ( 6 ) and the second outlet port ( 8 ) causing fluid and/or gas from the first inlet port ( 2 ) to not travel through the outer passage way ( 22 ).
[0039] FIG. 5 is an internal front view of the valve. Shown is the handle ( 10 ) which is coupled to the ball valve shaft ( 20 ) using the handle coupling mechanism ( 18 ). The handle is in the first position ( 16 ) thus allowing fluid and/or gas to flow from the first inlet port ( 2 ) through the first inner passage way ( 28 ) and out the first outlet port ( 4 ). In this configuration the second outlet port ( 8 ) which is in the second chamber ( 14 ) is not used. The ball valve ( 32 ) is in the first chamber ( 12 ), which is above the second chamber ( 14 ).
[0040] FIG. 6 is an internal front right perspective view of the inner workings with the outer casing removed in a preferred embodiment of a valve in a first position ( 16 ). In this figure, the handle ( 10 ) which sits on top of the first chamber ( 12 ) is in the first position ( 16 ). The ball valve ( 32 ) is shown to allow the first inner passage way ( 28 ) to be positioned for the flow of a fluid and/or gas between the first inlet port ( 2 ) and the first outlet port ( 4 ). In this configuration, the second inlet port ( 6 ) and the second outlet port ( 8 ) are not used.
[0041] FIG. 7 is an internal front right perspective view of the inner workings with the outer casing removed in a preferred embodiment of a valve in a second position ( 30 ). In this figure, the 3-way ball valve ( 32 ) is rotated by use of the handle ( 10 ) into the second position ( 30 ). In this configuration, fluid and/or gas from the first inlet port ( 2 ) passes to the second outlet port ( 8 ) through the outer passage way ( 22 ). Additionally, fluid and/or gas from the second inlet port ( 6 ) passes through the second inner passage way ( 26 ) to the second inlet port ( 6 ).
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A valve is disclosed that has an inlet and an outlet in fluid connection in a first position. When the valve is in a second position fluid enters the first inlet and exits the second outlet and enters in a second inlet and out the first outlet. The valve can be used for example to add a fluid circuit to a preexisting circuit.
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This invention relates to a method and apparatus for controlling foam in a vinegar fermentation process.
BACKGROUND OF THE INVENTION
In vinegar production, there have heretofore been two possible ways of dealing with the accumulation of foam during the fermentation process. One way entails the use of a mechanical defoamer or foam breaker, with the separated liquid portion of the foam being recirculated back into the fermentation tank, while in the other way it is necessary to permit the accumulating foam to overflow into a seperate collecting vessel. In either case, however, the foam, after being clarified and filtered, ultimately has to be reused in the fermentation process, because the quantity of foam that is generated is simply too large to be disposed of. In the production of high percentage alcohol vinegar, the foam formation is in the first instance dependent on the operational qualities of the fermenter. If the fermenter runs so well that a substantial harming of the vinegar bacteria is avoided, relatively little foam will be generated. If the fermenter operation, on the other hand, is mildly defective, which will be the case with most fermenters and may, for example, be due to a less than ideal aeration or cooling of the fermenting liquid or a deficiency in the injection of mash into the fermenter, the resultant appreciable harming of the vinegar bacteria will lead to a substantial generation of foam. This in and of itself might still be tolerable and permit the fermenter to be run without the aid of a defoamer.
One can never fully exclude the possibility, however, that a complete breakdown of the fermentation could occur, caused, for example, by a relatively brief power outage or by a running of the fermentation at a zero percent alcohol concentration in the event of a malfunction of the alcohol feed system. Should that happen, almost all the vinegar bacterial will die suddenly and an extraordinarily high degree of foaming will result, with liquid constituting up to 50% of the foam and it being impossible to discern the boundary between liquid and foam in the fermenter. If this foam were to be vented to the outside of the fermenter in the absence of a mechanical defoamer, the entire contents of the fermenter would be transformed into foam and emptied out of the same in a relatively brief time interval. Thus, the use of a mechanical defoamer or foam breaker is absolutely essential in such a case, in order to control the high foam pressure created in the fermenter and to minimize the formation of foam.
It might be noted, in passing, that in the production of malt vinegar, wine vinegar and fruit vinegar, the use of a mechanical defoamer is always required, because such mashes inherently tend to foam since they are infected with bacteria which die in the fermenter.
In order to avoid the necessity of having to break up the foam accumulating in a fermentation tank during a vinegar fermentation process completely into a gaseous and a liquid portion, it is known from Austrian Patent No. 206,866 and its corresponding U.S. Pat. No. 3,262,252, the disclosure of which is incorporated herein by this reference, to withdraw the foam from the fermenter into an apparatus which includes a generally cylindrical housing arranged to be traversed axially by the foam, and a motor-driven rotatable member or rotor disposed in the housing and journaled for rotation about an axis parallel to or coincident with the axis of the housing, the rotatable member comprising a hub or axle carrying a plurality of radial vanes defining therebetween a plurality of circumferentially adjacent, axially extending, cross-sectionally generally V-shaped, open-topped passageways. Thus, as the foam moves axially through the housing, it is subjected, when contacted by the vanes of the rotating member, to centrifugal forces, which leads to a radially outward displacement of the liquid portion of the foam and a separation thereof from the main gaseous portion and permits the gas to be axially withdrawn from the rotating member and the housing both liquid-free and foam-free. The liquid portion, which is so denoted even though it may still have some foam remnants (herein referred to as foam particles) attached to it, is removed through a liquid discharge outlet in the housing wall and is recycled into the fermentation tank for remixing with the fermentation substrate, in connection with which an unobstructed circuit for foam movement between the fermenter and the rotatable member is established in order to obviate having to undertake a complete, high energy-consuming, break-up of the foam into separate gaseous and liquid portions.
This circulation of the liquid portion of the foam back to the fermenter has proved to be satisfactory in regularly conducted fermentation processes but, when something interferes with the smooth running of the process, can lead to an excessive foam buildup, so that the drive motor for the rotating member becomes overloaded and the foam break-up is interrupted, which in turn can ultimately lead to an interruption of the entire fermentation process. Such an excessive foam build-up can, by way of example, occur during a submerged vinegar fermentation if the vinegar bacteria are damaged by virtue of an insufficiency in the oxygen supply, a too rapid change in either the alcohol concentration or the acetic acid concentration, or an operator's error.
BRIEF DESCRIPTION OF THE INVENTION
The objective of the present invention is to avoid the aforesaid drawbacks and disadvantages and to provide an improved method and apparatus for controlling the foam in a submerged vinegar fermentation process, which method and apparatus make it possible that the foam load can be substantially reduced without it being necessary to increase the energy required for the separation of the foam into gas and liquid fractions.
The invention achieves this objective by virtue of the fact that, contrary to what is done in the above-described known process, the liquid portion of the foam (possible, as previously mentioned, still carrying some foam remnants) which accumulates during the break-up of the foam is not recirculated to, and thus is eliminated from, the fermentation process.
By dispensing with a circulation of the liquid portion of the extracted foam back into the fermenter and utilizing instead thereof a removal of the liquid portion entirely from the fermentation process, the tendency for the foam to build up in the fermentation tank is surprisingly substantially reduced, apparently for the reason that the surface-active substances which result from a partial lysis of damaged bacteria and which constitute the principal source for the foam build-up, and which are extracted from the fermenter together with the foam, no longer reenter the fermentation substrate through the intermediary of the separated liquid portion and hence cannot initiate a fresh foam build-up in the fermenter. This results in a less turbulent fermentation process with a substantially reduced foam build-up, by virtue of which the overall fermentation process loses only an amount of liquid which is negligibly small relative to the volume of the fermentation substrate.
Since the elimination of the liquid portion of the foam from the fermentation process as a concomitant of the foam break-up tends to inhibit an increase in (i.e., an amplification of) the foam build-up which otherwise would occur by virtue of the recirculation of the foam-generating substances into the fermentation substrate, the foam build-up remains, even in the event of an operating breakdown, within generally tolerable limits. Over and above that, the reduced foam build-up leads to a lower energy requirement for the break-up of the foam, so that overall a higher operating efficiency can be achieved.
The liquid portion of the foam separated from the fermentation process can either be disposed of or further processed, e.g., by means of a special filtration, independently of the vinegar end product extracted from the fermentation process. With respect to such further processing, of course, a special capability exists by virtue of the present invention, namely, that the liquid foam portion separated from the fermentation process can be mixed with the extracted vinegar end product outside the fermenter. To this end, the liquid foam portion recovered from the at least temporarily continuing foam build-up is preferably collected and stored prior to any further processing thereof, which above all is highly recommended in the case of an intermittent accumulation of the end product.
For the performance of the process of the present invention, the starting point may be an apparatus of the general type disclosed in the abovementioned U.S. Pat. No. 3,262,252 and Austrian Patent No. 206,866. Such an apparatus thus would include a rotatable member or rotor journaled in a generally cylindrical housing, which member has a hub carrying a plurality of radial vanes and provides a plurality of axial recesses defined between the vanes. The apparatus would further be provided at one end face of the housing with a foam inlet opening connected to the fermenter, at the other end face of the housing with a gas exhaust opening, and in one region of the housing intermediate the opposite ends thereof with a liquid discharge opening. For the purposes of the present invention, in such an apparatus the discharge opening may then be connected with a drainage duct leading to a suitable location outside of the fermenter. On the other hand, in the event the liquid foam portion eliminated from the fermenter is not to be disposed of but rather is to be further processed, then the discharge opening can be connected via the drainage duct with a collecting vessel separate from the fermenter, in order to enable the liquid portion of the foam (which may, as mentioned, still have foam particles attached thereto) to be temporarily stored before being further processed alone or being admixed, for joint further processing, with the vinegar end product extracted from the fermenter.
The relatively limited quantity of foam that accumulates in the fermenter due to the practice of the present invention makes it possible to enhance the breaking of the foam into gas and liquid fractions without having to increase the requisite energy consumption for this purpose. To this end, the rotatable member may further include a surrounding cylinder or sleeve jointly rotatable therewith, which sleeve or cylinder is supported on the hub by means of the radial vanes (i.e., is attached to the vanes at their radially outwardmost end edges) and is provided in its wall with radial through openings located close to the vanes and trailing the same as viewed in the direction of rotation of the rotor. By virtue of this construction, the foam entering into the axially extending chambers of the rotatable member within the confines of the surrounding cylinder is, after its being engaged by the vanes, not centrifuged directly into the housing surrounding the rotating member but rather is compressed against the inner wall surface of the rotating cylinder and in particular first in the imperforate regions of the wall sections of the cylinder which are proximate to and ahead of (i.e., in leading relationship to) the respective vanes as viewed in the direction of rotation. Thus, the liquid foam portion accumulating in each space defined between two successive vanes must first spread out from the trailing one of the two vanes in the direction of rotation of the rotatable member along the respective section of the inner wall surface of the rotating cylinder up to the leading one of the two vanes before it can pass out of the cylinder and into the housing through the radial openings in the cylinder. The associated enhanced centrifugal force action thus aids the expulsion of the gas portion of the foam axially out of the rotatable member and thereby makes certain the sought-for improvement of the break-up of the foam into gas and liquid portions.
The reduction in the build-up of foam which is achieved by the method according to the present invention entails the advantage that it leads directly to a reduction in the size of the apparatus for breaking the foam up into gas and liquid portions. This makes it possible, especially in the case of smaller fermenters, to arrange the rotatable member not for rotation about a horizontal axis but rather for rotation about a vertical axis, with the foam inlet to the apparatus in the latter case consisting of an axial lower opening of the housing on the end section of the same which extends down into the fermenter, so that especially advantageous constructional conditions can be maintained which enable further simplifications to be achieved (e.g., the elimination of one of the bearings of the axle for the rotatable member) when the rotatable member is arranged in an endwise suspended position.
In accordance with another variant of the invention, the foam break-up apparatus need not be provided with a housing surrounding the vertically oriented rotatable member but instead can include, for facilitating the removal of the separated liquid portion, a rotatable member in which the cylinder or sleeve that is supported on the hub by means of the radial vanes has at least one end region projecting axially beyond the vanes, with the liquid drainage duct which extends to the outside of the fermenter being disposed in communication, by means of an intake opening oriented counter to the direction of rotation of the rotatable member, with the interior of that section of the cylinder which extends beyond the vanes. Through this construction, the liquid which accumulates against and rotates with the inner wall of the cylinder section that projects axially beyond the ends of the radial vanes is pressed into the drain conduit and is forced through the same out of the fermenter, all of which can be achieved with the aid of relatively minimal construction costs. Since the rotatable member in this variant is journaled for rotation about a vertical axis, the lower end section of the cylinder that extends downwardly beyond the vanes simultaneously defines the foam inlet of the apparatus. The rotational energy of the liquid in the region of the projecting section of the cylinder is then so great that a pressure feeding of the separated liquid even through a drainage duct directed upwardly out of the fermenter becomes possible.
The vertically disposed rotatable member, of course, needs to be driven only in case of an accumulation of a predetermined amount of foam. It is advantageous, therefore, to provide means for inhibiting a reverse flow of the separated liquid portion back into the fermenter from the drainage duct and the rotatable member whenever the rotation of the latter is interrupted. In accordance with another variant of the invention, such a reverse flow of the separated liquid back into the fermenter can advantageously be inhibited by providing a collecting channel at the lower end of the downwardly projecting section of the rotatable cylinder and disposing the intake end of the vertically upward running drainage duct so as to extend into the channel with the intake opening of the duct facing counter to the direction of rotation of the rotatable member. The same back flow prevention can, however, also be achieved by providing both the collecting channel and the intake opening of the drainage duct at the same end of the vertical cylinder of the rotatable member as where the gas exhaust opening of the latter is located, i.e., at the upper end of the cylinder.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects, characteristics and advantages of the present invention will be more clearly understood from the following detailed description thereof when read in conjunction with the accompanying drawings, in which:
FIG. 1 is a schematic vertical section through a fermenter designed for the performance of a submerged vinegar fermentation and including a foam control system provided with a foam break-up apparatus according to one embodiment of the present invention;
FIG. 2 is an axial section, on a greatly enlarged scale, through the foam break-up apparatus provided in the foam control system of FIG. 1;
FIG. 3 is a sectional view taken along the line III--III in FIG. 2;
FIG. 4 is a fragmentary schematic vertical section through a fermenter equipped with a modified form of the apparatus for breaking the accumulating foam into gas and liquid portions, the apparatus here having a rotatable member arranged for rotation about a vertical axis;
FIG. 5 is a view similar to FIG. 4 and shows a further modified foam-breaking apparatus which has a vertically rotatable member and a horizontal drainage duct for extracting the liquid portion of the broken-up foam directly from a collecting section of the associated rotatable cylinder;
FIG. 6 is a view similar to FIG. 5 and shows a still further modified version of the apparatus and a vertically upwardly extending drainage duct for extracting the liquid portion of the foam upwardly from the rotatable cylinder; and
FIG. 7 is a view similar to FIG. 6 and shows yet another modified form of the apparatus and an upwardly extending drainage duct for extracting the liquid portion of the foam upwardly from the rotatable member.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings in greater detail, FIG. 1 shows a fermenter F which is designed for performing submerged vinegar fermentations and in conventional manner includes a fermentation tank 1 provided at the bottom with a motor-driven aeration device 2, for example, an aerator such as is disclosed in U.S. Pat. No. 3,813,086. The aerator is connected with an air aspiration pipe 3 through which the quantity of air required to provide oxygen for the vinegar bacteria is aspirated from outside the tank via a filter 4, a metering valve 5 and a flow meter 6. A suitable, for example, solenoid-operated, control valve 7 and a delivery pump 8 are incorporated in a 15 discharge duct 7a connected at one end to the bottom of the fermentation tank and leading to a receiving vessel (not shown), in order to enable a predetermined quantity of the vinegar end product of the fermentation process to be extracted from the tank at the end of a specified fermentation period, for example, when a predetermined residual alcohol content of the fermentation substrate S has been attained in the fermenter. To enable an extracted quantity of the vinegar end product to be replaced by a quantity of fresh mash, the fermenter is provided with a feed pipe 12 located within and substantially axially of the tank and having its discharge end located in close proximity to the rotor (not shown) of the aeration device 2, the section 12a of the pipe exteriorly of the tank being connected with a mash reservoir (not shown) and having incorporated therein a feed pump 9, a metering valve 10 and a flow meter 11. This arrangement, which per se is well known, is designed to ensure a uniform and thorough mixing of the injected mash with the fermentation substrate S under simultaneous aeration.
The tank 1 at its top has an opening 1a sealed by a cover plate 1b on which is mounted an apparatus 14 according to one embodiment of the present invention for the dual purpose of extracting from the fermenter the foam which forms in the course of a submerged vinegar fermentation and accumulates in the tank space 1c above the top surface of the fermentation substrate, and of breaking up the accumulating foam into a gas portion and a liquid portion, the latter of which may have some residual foam particles adhering thereto. The apparatus 14 includes a horizontally oriented, cross-sectionally generally cylindrical housing 15 (see also FIGS. 2 and 3) which has end walls 15a and 15b provided with respective openings 15c and 15d. Of these, the opening 15c, which is larger than the opening 15d, is in communication with one end of a foam intake duct 13 that extends through the tank cover 1b into the tank 1, while the smaller opening 15d is in communication with one end of a gas vent or exhaust duct 20. The housing 15 at one side thereof has a generally tangential liquid discharge opening or outlet 15e which is in communication with a generally downwardly extending drainage duct 21. Rotatably mounted in the housing 15, through the intermediary of horizontal shaft members 17a and 17b journaled in respective bearings 17c and 17d, is a rotatable member or rotor 17 basically constructed of a hub or axle member 18 which is keyed to the shaft members 17a, 17b and carries a plurality of circumferentially spaced radial vanes 19 extending the full length of the hub. The vanes thus define therebetween a series of axially extending, generally V-shaped and radially outwardly flaring, passageways 19a into and through which foam withdrawn from the tank 1 via the duct 13 can pass. The shaft member 17a is connected with a drive motor 16 arranged to be activated and deactivated by a suitable control device 26 responsive to a foam level-sensing device 25 extending into the tank. The sensing device 25, details of which are not shown but which is well known per se, in conventional fashion includes two spaced electrodes electrically insulated from each other and connected with the energization circuit for the control device 26. The arrangement is such that when foam enters the space between and contacts the two electrodes, the said energization circuit is closed and the motor 16 set into operation to drive the rotor 17.
It will be apparent, therefore, that in operation of the apparatus 14 as so far described (in which the rotor 17 has essentially the same form as the rotor of the foam break-up apparatus described in U.S. Pat. No. 3,262,252 and Austrian Patent No. 206,866), any foam entering the housing 15 and moving along the path extending between the openings 15c and 15d and through the passageways 19a is engaged by the vanes 19. It will be understood, in this regard, that when foam in the fermenter space 1c builds up to the foam entry opening of the apparatus 14, there is immediately created, by virtue of the smaller area of the gas exhaust opening 15d relative to the foam entry opening 15c, an overpressure in the fermenter which forces the foam into the apparatus 14. Thus, when the rotor 17 is in rotation, the centrifugal forces exerted on the foam flowing axially through the passageways 19a cause a breaking up of the foam, i.e., a separation of the liquid portion of the foam from the gas portion thereof. This is due to the fact that the gas portion, by virtue of its lighter mass, remains closer to the hub of the rotor 17 and is removed axially from the housing through the exhaust opening 15d and the 15d and the exhaust duct 20, whereas the heavier, possibly still foam-loaded, liquid portion is centrifuged radially out of the open-topped passageways 19a of the rotor 17 into the housing 15 and is removed therefrom through the discharge opening 15e and the drainage duct 21. The liquid fraction then can be either disposed of (not shown) or alternatively can be led via the duct 21 into a collecting vessel 22 for storage preparatory to being subjected to a further processing.
By means of this manner of total elimination of the liquid portion of the accumulating foam from the fermentation process, i.e., without any recirculation of the liquid back into the fermentation tank, a further foam build-up that could be caused by the surface-active substances found in this liquid portion (such surface-active substances result from a partial lysis of harmed vinegar bacteria and actually cause the foaming) is avoided. As a consequence, the vinegar fermentation is rendered less turbulent and a substantially minimized foam formation can be expected. Such a minimized foam formation also permits the liquid portion accumulating during the break-up of the foam to be separated from the fermentation process without causing any problems in the latter due to loss of liquid, because the removed liquid portion has a negligibly small volume relative to the contents of the fermenter.
As previously indicated, the liquid portion of the foam accumulating and stored in the collecting vessel 22 can be extracted from the vessel as needed, and in particular this can be done advantageously at the time of an extraction of vinegar end product from the fermenter, in order to enable the accumulated liquid portion to be mixed and further processed with the extracted vinegar. For this purpose, the collecting vessel 22 is connected to the intake side of the delivery pump 8 by means of a discharge conduit 23 and through a suitable control valve 24, while at the same time the control valve 7 is open as well. The vessel can, however, also be connected via the control valve 24 and the feed pump 8 directly to a further processing location, for example, a filtration system, without being mixed with the vinegar end product, and at such time the valve 7 would, of course, be closed.
By virtue of the minimal foam formation achieved by the method of the present invention, the apparatus 14 is designed to be activated only upon a predetermined foam build-up in the tank 1. To this end, the foam sensor 25 serves to detect the height of the accumulated foam in the fermenter and to energize the motor 16 through the control device 26 in dependence on the detected foam height. In order, however, in accordance with a refinement of the present invention, to prevent an undesired power-consuming and energy-wasting energization of the motor 16 by foam particles becoming or remaining stuck between the electrodes of the foam sensing device even though the foam level may be or have sunk below that of the sensor electrodes 25, the latter can also be arranged in the gas exhaust duct 20, i.e., beyond the location of the gas exhaust opening 15d, as is indicated in dot-dash lines at 25' in FIG. 2. With such an arrangement, it will be understood, the sensor electrodes will be contacted by foam and the motor will be started only when and as soon as some of the foam has been forced through and out of the rotor 17 via the gas exhaust opening 15d by the overpressure existing in the fermentation tank. Once the rotor starts rotating, of course, further passage of foam through the opening 15d stops immediately. Since that would also stop the motor (the flow of gas out of the rotor would have blown any foam particles off the sensor electrodes 25'), a time delay holding relay (not shown) is provided to maintain the motor energization circuit closed for a predetermined time interval sufficient to reduce the built-up foam in the fermenter to a desired level. After the relay has stopped the motor, the cycle is repeated, with foam building up and some of it eventually contacting the sensor electrodes 25' to again start the motor and lock in the holding relay until the preset time interval of operation of the apparatus 14 has expired.
The minimal foam build-up achieved by the present invention further makes it possible to achieve an even better break-up of the foam. For this purpose the rotor 17 is provided with a jointly rotatable cylinder or sleeve 27 affixed to and supported by the vanes 19 at their radially outwardmost extremities, so that the axial foam passageways 19a defined between the radial vanes 19 are closed at their radially outer peripheries by the respective segmental sections of the cylindrical sleeve 27. In conjunction therewith, the sleeve 27 is provided with a plurality of through openings 28 for permitting escape of the liquid portion of the foam into the housing 15, the openings being arranged in sections of the sleeve wall which are adjacent the vanes 19 but trail the same as viewed in the direction of rotation of the rotatable member 17 (see FIG. 3). The arrangement is such that the liquid foam portion which is centrifugally displaced radially outwardly of the rotor in the passageways 19a first accumulates at and is compressed against the imperforate regions of the wall sections of the sleeve or cylinder 27, i.e., at the regions 27a of those wall sections which are adjacent to but are ahead of or lead the respective vanes as viewed in the direction of rotation, and only then spreads or expands over the remainders of the wall sections up to the locations of the respective through openings 28 adjacent the next successive vanes 19, to enable the liquid portion of the foam to be slung or centrifuged outwardly through the openings 28 into the housing 15. In this way, a somewhat larger quantity of gas than would otherwise be the case is separated from the liquid portion of the foam, which has the advantageous effect of minimizing the required take-up volume of the collecting vessel 22.
In the embodiment of the invention illustrated in FIGS. 1-3, the apparatus 14 for breaking up the accumulating foam into liquid and gas portions is conventionally arranged with its axis of rotation oriented horizontally on the fermentation tank 1. However, the reduced energy consumption for the foam break-up made possible by the minimized foam build-up in the fermenter through the method of the present invention further provides the capability, especially in the case of smaller fermenters, of arranging on the tank 1 an apparatus 14a (see FIG. 4) which is provided with a rotor 17 mounted for rotation about a vertical axis of rotation. In this embodiment of the invention, the associated housing 15', which surrounds the rotor 17 and in which an axial end opening 15c, as before, defines the foam inlet 13a of the apparatus, extends endwise down into the fermenter, with the shaft 17e which carries the hub 18 of the rotatable member 17 advantageously being supported at one end only (the upper end) and enabling the attainment of a foam intake unobstructed by a bearing for the shaft. All other parts of the apparatus 14 a are essentially the same as in the embodiment of FIGS. 1-3, except that no special foam intake duct 13 is required and that the generally downwardly slanted drainage duct 21 extends through the tank 1 and communicates with the housing 15' adjacent the free end thereof where the cylindrical wall of the housing adjoins a radial end flange 15f thereof which defines the end face of the housing and the opening 15c therein.
The apparatus according to the present invention for breaking up the foam in the fermenter into liquid and gas portions can also be constructed to have a rotor mounted for rotation about a vertical axis but without being enclosed in a surrounding stationary housing. This variant construction can be incorporated in embodiments of the invention represented by FIGS. 5, 6 and 7.
More particularly, in each of the embodiments of FIGS. 5 and 6 the respective apparatus 14b or 14b' includes a vaned rotatable member, designated 17' in FIG. 5 and 17" in FIG. 6, the cylindrical sleeve 27' or 27" of which is imperforate throughout. In each case, however, the sleeve extends downwardly into the fermenter beyond the lower ends of the respective radial vanes 19 and thereby provides a projecting cylindrical section 29 at the lower end of which the foam inlet 13b is defined by a radially inwardly directed annular end flange 29a. In the embodiment of FIG. 5, the liquid foam portion separated by centrifugal force from the gas portion during the rotation of the rotor 17' accumulates in the section 29 interiorly of the cylinder and above the annular end flange. To enable this liquid portion of the foam to be extracted directly from the interior of the sleeve section 29, the drainage duct 21', which is shown as oriented horizontally but may be downwardly inclined, is provided with an intake end section 21a' which extends into the sleeve section 29 and there has an inlet opening 30 positioned close to the inner wall surface of the sleeve section 29 just above the end flange 29a and oriented counter to the direction of rotation of the rotatable member 17'. Thus, the liquid accumulating in the cylinder 27' and rotating therewith is forced into the drainage duct 21'.
The same principle makes it possible, in the embodiment of FIG. 6, to provide an apparatus 14b' which includes a drainage duct 21" that extends vertically upwardly out of the fermenter through the tank cover supporting the apparatus 14b'. However, in this embodiment measures must be taken to inhibit any reverse flow of the liquid in the discharge conduit 21" back into the fermenter 1 when the rotation of the rotatable member 17" is interrupted. To this end, the downwardly projecting section 29 of the cylinder or sleeve 27" is further provided with an axial annular flange 29b at the inner periphery of the radial end flange 29a so as to define an upwardly open collecting channel 31 at the free end of the cylinder section 29. The intake end section 21a" of the drainage duct 21" here projects into the channel 31 and has its inlet opening 30a positioned close to the bottom of the channel and, as before, oriented counter to the direction of rotation of the rotatable member 17". The volume of the channel 31 must, of course, be sufficient to enable the channel to catch and retain all of the separated liquid that is present in and flows back downwardly out of the vertically rising drainage duct when the rotation of the rotor is interrupted.
The same principle is also applicable to an apparatus 14b" according to the embodiment of FIG. 7, where the cylinder or sleeve 27'" surrounding the vanes 19 of the rotor 17'" is of the same length as the vanes. Here, however, the sleeve 27'" is provided at its upper end region, i.e., the end region where the gas exhaust opening is located, with a plurality of circumferentially distributed radial openings 32 and an exterior upwardly open collecting channel 33 of appropriate volume which is in communication with the interior of the sleeve through the openings 32. The intake end section 21a'" of the vertically upwardly extending drainage duct 21'" projects from above down into the channel 33 and has its inlet opening 30b positioned close to the bottom of the channel and oriented counter to the direction of rotation of the rotor 17'".
It will be understood that the foregoing description of preferred embodiments of the present invention is for purposes of illustration only, and that the various structural and operational features herein disclosed are susceptible to a number of modifications and changes none of which entails any departure from the spirit and scope of the present invention as defined in the hereto appended claims.
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A method and apparatus for controlling the foam in a vinegar fermentation process. As in the prior art, the foam accumulating on the upper surface of the fermentation substrate is moved along a given path axially through a rotor of the apparatus and revolved about the path by the rotor so as to be subjected to centrifugal forces and broken up into a gas portion which is exhausted in the direction of movement along the path and a liquid portion, possibly still including some foam particles, which is separated from the gas portion in a direction radially of the path. According to the invention, in order to minimize the foam accumulation in the fermentation tank, it is proposed to completely eliminante the liquid portion of the broken-up foam from the fermentation process, i.e., not to recycle the separated liquid portion into the fermentation tank, either by disposing of it or by further processing it and/or mixing it with the recovered vinegar end product apart from the fermentation process.
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DISCLOSURE OF THE INVENTION
This invention relates to novel O-sulfates of 6(or 5)-hydroxy-2-benzothiazolesulfonamide which are useful in the reduction of elevated intraocular pressure. More particularly this invention relates to the sulfates having the structural formula: ##STR1## where M.sup.⊕ is an opthalmologically acceptable cation such as sodium, potassium, ammonium, tetra(C 1-4 alkyl)-ammonium, especially tetra-n-butyl ammonium, pyridinium, imidazolium, pralidoxime or thiamine. This invention also relates to ophthalmic compositions that are employed in the treatment of elevated intraocular pressure, especially when accompanied by pathological damage such as in the disease known as glaucoma.
BACKGROUND OF THE INVENTION
Glaucoma is an ocular disorder associated with elevated ocular pressures which are too high for normal function and may result in irreversible loss of visual function. If untreated, glaucoma may eventually lead to blindness. Ocular hypertension, i.e., the condition of elevated intraocular pressure without optic nerve head damage or characteristic glaucomatous visual field defects, is now believed by many ophthalmologists to represent the earliest phase of glaucoma.
Many of the drugs formerly used to treat glaucoma proved not entirely satisfactory. Indeed, few advances were made in the treatment of glaucoma since pilocarpine and physostigmine were introduced. Only recently have clinicians noted that many β-adrenergic blocking agents are effective in reducing intraocular pressure. While many of these agents are effective in reducing intraocular pressure, they also have other characteristics, e.g. membrane stabilizing activity, that are not acceptable for chronic ocular use.
(S)-1-tert-butylamino-3-[(4-morpholino-1,2,5-thiadiazol-3-yl)oxy]-2-propanol, a β-adrenergic blocking agent, was found to reduce intraocular pressure and to be devoid of many unwanted side effects associated with pilocarpine and, in addition, to possess advantages over many other β-adrenergic blocking agents, e.g. to be devoid of local anesthetic properties, to have a long duration of activity, and to display minimal tolerance.
Although pilocarpine, physostigmine and β-blocking agents reduce intraocular pressure, none of these drugs manifests its action by inhibiting the enzyme carbonic anhydrase and, thereby, impeding the contribution made by the carbonic anhydrase pathway to aqueous humor formation.
Agents referred to as carbonic anhydrase inhibitors block or impede this inflow pathway by inhibiting the enzyme, carbonic anhydrase. While such carbonic anhydrase inhibitors are now used to treat intraocular pressure by oral, intravenous or other systemic routes, they thereby have the distinct disadvantage of inhibiting carbonic anhydrase throughout the entire body. Such a gross disruption of a basic enzyme system is justified only during an acute attack of alarmingly elevated intraocular pressure, or when no other agent is effective. Despite the desirability of directing the carbonic anhydrase inhibitor only to the desired ophthalmic target tissue, no topically effective carbonic anhydrase inhibitors are available for clinical use.
DETAILED DESCRIPTION OF THE INVENTION
The novel compound of this invention has the structural formula: ##STR2## wherein M.sup.⊕ is an ophthalmologically acceptable cation such as sodium, potassium, ammonium, tetra(C 1-4 alkyl)ammonium, especially tetra-n-butyl ammonium, pyridinium, imidazolium, pralidoxime or thiamine and the sulfate substituent is in the 5 or 6-position.
It is preferred that the sulfate substituent occupy the 6-position, and that M + represents sodium, potassium or ammonium.
The compounds of this invention are most suitably prepared by reacting a compound of the formula: ##STR3## with sulfamic acid in pyridine at elevated temperatures for about 3 to 12 hours to provide the ammonium salt (M + =NH 4 + ) followed if desired by titration with hydroxides of the formula MOH.
The reaction may be conducted at temperatures of from 50° C. to the boiling point of the solvent.
The following example describes the general preparative method employed.
EXAMPLE 1
6-hydroxybenzothiazole-2-sulfonamide-O-sulfate, ammonium salt
Sulfamic acid, 9.3 g (0.096 mol) was added to a solution of 6-hydroxybenzothiazole-2-sulfonamide (9.2 g, 0.04 mol) in 200 mL of pyridine. The mixture was heated to 90°-95° internal temperature for 6 hours. The mixture was cooled to approximately 50° C. and the pyridine was distilled from the product at reduced pressure. The residue was dissolved in water (200 mL) and extracted with ethyl acetate. The aqueous layer was made basic with NH 4 OH and was evaporated. The residue was stirred with 225 mL of 95% ethanol for 10 minutes. The mixture was filtered and evaporated. The residue was again dissolved in ethanol (200 mL), and a further quantity of insoluble material was removed by filtration. After evaporation of the solvent, the residue was dissolved in methanol and precipitated by addition of 10 volumes of ether. The product was collected by suction filtration and dried at 90° C. for 4 hours under high vacuum. Yield, 6.32 gm; m.p. 226-228 (d). 1 H-NMR (CD 3 OD)δ 8.0-8.2 (m, 2H); 7.52 (1H, dd, J=9 and 2).
Elemental Analysis Calcd. for C 7 H 9 N 3 O 6 S 3 .1/2H 2 O: C, 25.00; H, 3.00; N, 12.54. Found: C, 24.72; H, 2.71; N, 12.54.
The sodium and other salts are obtained by titration of the ammonium salt with the appropriate hydroxide in aqueous solution. Evaporation of the solvent leaves the solid. The sodium salt prepared in this manner had m.p. >300° C.
For use in treatment of conditions relieved by the inhibition of carbonic anhydrase, the active compound can be administered either systemically, or, in the treatment of the eye, topically. The dose administered can be from as little as 0.1 to 25 mg or more per day, singly, or preferably on a 2 to 4 dose per day regimen although a single dose is satisfactory.
When administered for the treatment of elevated intraocular pressure or glaucoma, the active compound is most desirably administered topically to the eye, although systemic treatment is also satisfactory.
When given systemically, the drug can be given by any route, although the oral route is preferred. In oral administration the drug can be employed in any of the usual dosage forms such as tablets or capsules, either in a contemporaneous delivery or sustained release form. Any number of the usual excipients or tableting aids can likewise be included.
When given by the topical route, the active drug is formulated into an opthalmic preparation.
In such formulations, from 0.1% to 15% by weight can be employed. The objective is to administer a dose of from 0.1 to 10 mg per eye per day to the patient, with treatment continuing so long as the condition persists.
Thus, in an ophthalmic solution, insert, ointment or suspension for topical delivery, or a tablet, intramuscular, or intravenous composition for systemic delivery, the active medicament is employed, the remainder being carrier, excipients, preservatives and the like as are customarily used in such compositions.
The active drug of this invention is most suitably administered in the form of ophthalmic pharmaceutical compositions adapted for topical administration to the eye such as a suspension, ointment, or as a solid insert. Formulations of these compounds may contain from 0.01 to 15% and especially 0.5% to 2% of medicament. Higher dosages as, for example, about 10%, or lower dosages can be employed provided the dose is effective in reducing or controlling elevated intraocular pressure. As a unit dosage from between 0.001 to 10.0 mg, preferably 0.005 to 2.0 mg, and especially 0.1 to 1.0 mg of the compound is generally applied to the human eye, generally on a daily basis in single or divided doses so long as the condition being treated exists.
These hereinbefore described dosage values are believed accurate for human patients and are based on the known and presently understood pharmacology of the compounds, and the action of other similar entities in the human eye. They reflect the best mode known. As with all medications, dosage requirements are variable and must be individualized on the basis of the disease and the response of the patient.
The thrust of this invention as hereinbefore stated is to provide an ocular antihypertensive agent for the dye, both human and animal, that acts by inhibiting carbonic anhydrase and, thereby, impeding the formation of aqueous humor.
The pharmaceutical preparation which contains the active compound may be conveniently admixed with a non-toxic pharmaceutical organic carrier, or with a non-toxic pharmaceutical inorganic carrier. Typical of pharmaceutically acceptable carriers are, for example, water, mixtures of water and water-miscible solvents such as lower alkanols or aralkanols, vegetable oils, polyalkylene glycols, petroleum based jelly, ethyl cellulose, ethyl oleate, carboxymethylcellulose, polyvinylpyrrolidone, isopropyl myristate and other conventionally employed acceptable carriers. The pharmaceutical preparation may also contain non-toxic auxiliary substances such as emulsifying, preserving, wetting agents, bodying agents and the like, as for example, polyethylene glycols 200, 300, 400 and 600, carbowaxes 1,000, 1,500, 4,000, 6,000 and 10,000, antibacterial components such as quaternary ammonium compounds, phenylmercuric salts known to have cold sterilizing properties and which are non-injurious in use, thimerosal, methyl and propyl paraben, benzyl alcohol, phenyl ethanol, buffering ingredients such as sodium chloride, sodium borate, sodium acetates, gluconate buffers, and other conventional ingredients such as sorbitan monolaurate, triethanolamine, oleate, polyoxyethylene sorbitan monopalmitylate, dioctyl sodium sulfosuccinate, monothioglycerol, thiosorbitol, ethylenediamine tetracetic acid, and the like. Additionally, suitable ophthalmic vehicles can be used as carrier media for the present purpose including conventional phosphate buffer vehicle systems, isotonic boric acid vehicles, isotonic sodium chloride vehicles, isotonic sodium borate vehicles and the like. The pharmaceutical preparation may also be in the form of a solid insert.
While many patients fluid liquid medication to be entirely satisfactory, others may prefer a solid medicament that is topically applied to the eye, for example, a solid dosage form that is suitable for insertion into the cul-de-sac. To this end the carbonic anhydrase inhibiting agent can be included with a non-bioerodible insert, i.e. one which after dispensing the drug remains essentially intact, or a bioerodible insert, i.e. one that either is soluble in lacrimal fluids, or otherwise disintegrates. While the insert employed is not critical and those disclosed in U.S. Pat. No. 3,630,200 Higuchi; U.S. Pat. No. 3,811,444 Heller et al.; U.S. Pat. No. 4,177,256 Michaels et al.; U.S. Pat. No. 3,868,445 Ryde et al.; U.S. Pat. No. 3,845,201 Haddad; U.S. Pat. No. 3,981,303 Higuchi; and U.S. Pat. No. 3,867,519 Michaels, are satisfactory; in general, however, the insert described below is found preferable.
For example, one may use a solid water soluble polymer as the carrier for the medicament. The polymer used to form the insert may be any water soluble non-toxic polymer, for example, cellulose derivatives such as methylcellulose, sodium carboxymethyl cellulose, or a hydroxy lower alkyl cellulose such as hydroxyethyl cellulose, hydroxypropyl cellulose, hydroxypropylmethyl cellulose and the like; acrylates such as polyacrylic acid salts, ethyl acrylates, polyacrylamides; natural products such as gelatin, alginates, pectins, tragacanth, karaya, chondrus, agar, acacia; the starch derivatives such as starch acetate, hydroxyethyl starch ethers, hydroxypropyl starch, as well as other synthetic derivatives such as polyvinyl alcohol, polyvinyl pyrrolidone, polyvinyl methyl ether, polyethylene oxide, neutralized carbopol and xanthan gum, and mixtures of said polymer.
Preferably the solid insert is prepared from cellulose derivatives such as methylcellulose, hydroxyethyl cellulose, hydroxypropyl cellulose or hydroxypropylmethyl cellulose or from other synthetic materials such as polyvinyl alcohol, polyvinyl pyrrolidone, polyethylene oxide or polyvinyl methylether. Hydroxypropyl cellulose, one of the preferred polymers for the preparation of the insert, is available in several polymeric forms, all of which are suitable in the preparation of these inserts. Thus, the product sold by Hercules, Inc. of Wilmington, Del., under the name KLUCEL such as KLUCEL HF, HWF, MF, GF, JF, LF and EF which are intended for food or pharmaceutical use, are particularly useful. The molecular weight of these polymers useful for the purposes described herein may be at least 30,000 to about 1,000,000 or more. Similarly, an ethylene oxide polymer having a molecular weight of up to 5,000,000 or greater, and preferably 100,000 to 5,000,000 can be employed. Further, for example, POLYOX, a polymer supplied by Union Carbide Co., may be used having a molecular weight of about 50,000 to 5,000,000 or more and preferably 3,000,000 to 4,000,000. Other specific polymers which are useful are polyvinyl pyrrolidine having a molecular weight of from about 10,000 to about 1,000,000 or more, preferably up to about 350,000 and esecially about 20,000 to 60,000; polyvinyl alcohol having a molecular weight of from about 30,000 to 1,000,000 or more, particularly about 400,000 and especially from about 100,000 to about 200,000; hydroxypropylmethyl cellulose having a molecular weight of from about 10,000 to 1,000,000 or more, particularly up to about 200,000 and especially about 80,000 to about 125,000; methyl cellulose having a molecular weight of from about 10,000 to about 1,000,000 or more, preferably up to about 200,000 and especially about 50 to 100,000; and CARBOPOL (carboxyvinyl polymer) of B. F. Goodrich and Co. designated as grades 934, 940 and 941. It is clear that for the purpose of this invention the type and molecular weight of the polymer is not critical. Any water soluble polymers can be used having an average molecular weight which will afford dissolution of the polymer and, accordingly, the medicament in any desired length of time. The inserts, therefore, can be prepared to allow for retention and, accordingly, effectiveness in the eye for any desired period. The insert can be in the form of a square, rectangle, oval, circle, doughnut, semi-circle, 1/4 moon shape, and the like. Preferably the insert is in the form of a rod, doughnut, oval or 1/4 moon. The insert can be prepared readily, for example, by dissolving the medicament and the polymer in a suitable solvent and the solution evaporated to afford a thin film of the medicated polymer which can then be subdivided to prepare inserts of appropriate size. Alternatively the insert can be prepared by warming the polymer and the medicament and the resulting mixture molded to form a thin film. Preferably, the inserts are prepared by molding or extrusion procedures well known in the art. The molded or extruded product can then be subdivided to afford inserts of suitable size for administration in the eye. The insert can be of any suitable size which readily fits into the eye. For example, castings or compression molded films having a thickness of about 0.25 mm. to 15.0 mm. can be subdivided to obtain suitable inserts. Rectangular segments of the cast or compressed film having a thickness between about 0.5 and 1.5 mm. can be cut to afford shapes such as rectangular plates of 4×5-20 mm. or ovals of comparable size. Similarly, extruded rods having a diameter between about 0.5 and 1.5 mm. can be cut into suitable sections to provide the desired amount of medicated polymer. For example, rods of 1.0 to 1.5 mm. in diameter and about 20 mm. long are found to be satisfactory. The inserts may also be directly formed by injection molding. It is preferred that the ophthalmic inserts containing the medicament of the present invention be formed so that they are smooth and do not have any sharp edges or corners which could cause damage to the eye. Since the term smooth and sharp edges or corners are subjective terms, in this application these terms are used to indicate that excessive irritation of the eye will not result from the use of the insert.
The medicated ocular inserts can also contain plasticizers, buffering agents and preservatives. Plasticizers suitable for this purpose must, of course, also be completely soluble in the lacrimal fluids of the eye. Examples of suitable plasticizers that might be mentioned are water, polyethylene glycol, propylene glycol, glycerine, trimethylol propane, di and tripropylene glycol, hydroxypropyl sucrose and the like. Typically, such plasticizers can be present in the ophthalmic insert in an amount ranging from 0% up to about 30% by weight. A particularly preferred plasticizer is water which is present in amounts of at least about 5% up to 40%. In actual practice, a water content of from about 10% to about 20% is preferred since it may be easily accomplished and adds the desired softness and pliability to the insert.
When plasticizing the solid medicinal product with water, the product is contacted with air having a relative humidity of at least 40% until said product picks up at least about 5% water and becomes softer and more pliable. In a preferred embodiment, the relative humidity of the air is from about 60% to about 99% and the contacting is continued until the water is present in the product in amounts of from about 10% to about 20%.
Suitable water soluble preservatives which may be employed in the insert are sodium bisulfate, sodium thiosulfate, ascorbate, benzalkonium chloride, chlorobutanol, thimerosal, phenylmercuric acetate, phenylmercuric borate, parabens, benzyl alcohol and phenylethanol. These agents may be present in amounts of from 0.001 to 5% by weight of solid insert, and preferably 0.1 to 2%.
Suitable water soluble buffering agents are alkali, alkali earth carbonates, phosphates, bicarbonates, citrates, borates, and the like, such as sodium phosphate, citrate, borate, acetate, bicarbonate and carbonate. These agents may be present in amounts sufficient to obtain a pH of the system of between 5.5 to 8.0 and especially 7-8; usually up to about 2% by weight of polymer. The insert may contain fom about 1 mg. to 100 mg. of water soluble polymer, more particularly fom 5 to 50 mg. and especially from 5 to 20 mg. The medicament is present from about 0.1 to about 25% by weight of insert.
The following examples of ophthalmic formulations are given by way of illustration.
EXAMPLE 2
______________________________________Solution Composition______________________________________6-hydroxybenzothiazole- 1 mg. 15 mg.2-sulfonamide-O--sulfate,ammonium saltMonobasic sodium phosphate.2H.sub. 2 O 9.38 mg. 6.10 mg.Dibasic sodium phosphate.12H.sub. 2 O 28.48 mg. 16.80 mg.Benzalkonium chloride 0.10 mg. 0.10 mg.Water for injection q.s. ad. 1.0 ml. 1.0 ml.______________________________________
The sterile components are added to and dissolved in sterile water. The pH of the suspension is adjusted to 6.8 sterilely and diluted to volume.
EXAMPLE 3
______________________________________6-Hydroxybenzothiazole- 5 mg.2-sulfonamide-O--sulfate,ammonium saltpetrolatum q.s. ad. 1 gram______________________________________
The compound and the petrolatum are aseptically combined.
EXAMPLE 4
______________________________________6-Hydroxybenzothiazole- 1 mg.2-sulfonamide-O--sulfate,ammonium saltHydroxypropylcellulose q.s. 12 mg.______________________________________
Ophthalmic inserts are manufactured from compression molded films which are prepared on a Carver Press by subjecting the powdered mixture of the above ingredients to a compressional force of 12,000 lbs. (guage) at 300° F. for one to four minutes. The film is cooled under pressure by having cold water circulate in the platen. Ophthalmic inserts are then individually cut from the film with a rod-shaped punch. Each insert is placed into a vial, which is then placed in a humidity cabinet (88% R.H. at 30° C.) for two to four days. After removal from the humidity cabinet, the vials are stoppered and then capped. The vials containing the hydrate insert are then autoclaved at 250° F. for 1/2 hour.
EXAMPLE 5
______________________________________6-Hydroxybenzothiazole- 1 mg.2-sulfonamide-O--sulfate,sodium saltHydroxypropyl cellulose q.s. ad. 12 mg.______________________________________
Ophthalmic inserts are manufactured from a solvent cast film prepared by making a viscous solution of the powdered ingredients listed above using methanol as the solvent. The solution is placed on a Teflon plate and allowed to dry at ambient conditions. After drying, the film is placed in an 88% R.H. cabinet until it is pliable. Appropriately sized inserts are cut from the film.
EXAMPLE 6
______________________________________6-Hydroxybenzothiazole- 1 mg.2-sulfonamide-O--sulfate,sodium saltHydroxypropyl methyl cellulose q.s. ad. 12 mg.______________________________________
Ophthalmic inserts are manufactured from a solvent cast film which is prepared by making a viscous solution of the powdered blend of the above ingredients using a methanol/water solvent system (10 ml. methanol is added to 2.5 g. of the powdered blend, to which 11 ml. of water (in three divided portions) is added. The solution is placed on a Teflon plate and allowed to dry at ambient conditions. After drying, the film is placed in an 88% R.H. cabinet until it is pliable. Appropriately sized inserts are then cut from the film.
EXAMPLE 7
______________________________________6-Hydroxybenzothiazole- 1 mg.2-sulfonamide-O--sulfate,sodium saltHydroxypropylmethyl cellulose q.s. ad. 12 mg.______________________________________
Ophthalmic inserts are manufactured from compression molded films which are prepared on a Carver Press by subjecting the powdered mixture of the above ingredients to a compressional force of 12,000 lbs. (guage) at 350° F. for one minute. The film is cooled under pressure by having cold water circulate in the platen. Ophthalmic inserts are then individually cut from the film with a punch. Each insert is placed into a vial, which is then placed in a humidity cabinet (88% R.H. at 30° C.) for two to four days. After removal from the humidity cabinet, the vials are stoppered and then capped. The vials containing the hydrated insert are then autoclaved at 250° F. for one-half hour.
It is highly preferred that the solid inserts of this invention are available for use by the patient in a pathogen free condition. Thus, it is preferred to sterilize the inserts and so as insure against recontamination, the sterilization is preferably conducted after packaging. The best mode of sterilizing is to employ ionizing irradiation including irradiation emanating from Cobalt 60 or high energy electron beams.
After packaging a convenient quantity of inserts, usually a single dose, the package is exposed to a sterilizing quantity of radiation. The preferred packaging employs sealing the inserts between layers of film or foil and then sealing or laminating the layers together about the edges. The techniques for performing the sterilization are well known and accepted, for example, as outlined in International Atomic Energy Commission, Code of Practice for Radiosterilization of Medical Products, 1967, pp. 423-431; and Block, Disinfection, Sterilization and Preservation, 2nd Ed., Lea & Febinger, Philadelphia, 1977, pp. 542-561.
The required quantity of irradiation can be determined experimentally by testing irradiated inserts for viable bacteria. Generally, the amount of irradiation desired to achieve sterilization is defined by the D 10 value. The D 10 value is the radiation dose that will reduce a given population of organisms by a factor of 10. Based on D 10 values, experimentally obtained for Bacillus pumilus, and presterilization contamination levels, a dose of 1.36 megarads is effective in obtaining a sterile product.
Other formulations, in an oil vehicle and an ointment are exemplified in the following examples.
EXAMPLE 8
______________________________________6-hydroxybenzothiazole-2- 0.1 mg.sulfonamide-O--sulfate, ammonium saltPeanut oil q.s. ad. 0.10 mg.______________________________________
EXAMPLE 9
______________________________________6-hydroxybenzothiazole-2- 0.5 gramsulfonamide-O--sulfate, ammonium saltPetrolatum q.s. ad. 1 gram______________________________________
The compound, as the ammonium salt and the petrolatum are aseptically combined.
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Novel O-sulfates of 6(or 5)-hydroxy-2-benzothiazolesulfonamide are useful for the topical treatment of elevated intraocular pressure. Opthalmic compositions include drops and inserts.
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BACKGROUND
This invention relates to mobile communications and, more particularly, to managing packet data interconnections in a mobile communication network.
All modern mobile communication systems have a hierarchical arrangement, in which a geographical “coverage area” is partitioned into a number of smaller geographical areas called “cells.” Referring to FIG. 1 , each cell is preferably served by a Base Transceiver Station (“BTS”) 102 a . Several BTS 102 a–n are centrally administered via fixed links 104 a–n by a Base Station Controller (“BSC”) 106 a . The BTSs and BSC are sometimes collectively referred to as the Base Station Subsystem (“BS”) 107 . Several BSCs 106 b–n may be centrally administered by a Mobile Switching Center (“MSC”) 110 via fixed links 108 a–n.
MSC 110 acts as a local switching exchange (with additional features to handle mobility management requirements, discussed below) and communicates with the phone network (“PSTN”) 120 through trunk groups. U.S. mobile networks include a home MSC and a Gateway MSC. The home MSC is the MSC corresponding to the exchange associated with a Mobile Subscriber (also referred to as a Mobile Station or “MS”); this association is based on the phone number, such as the area code, of the MS. Examples of an MS include a hand-held device such as a mobile phone, a PDA, a 2-way pager, or a laptop computer, or Mobile Unit Equipment such as equipment that is not self-propelled and that does not have an operator, such as a mobile unit attached to a refrigerator van or a rail car, a container, or a trailer.
The home MSC is responsible for a Home Location Register (“HLR”) 118 discussed below. The Gateway MSC, on the other hand, is the exchange used to connect the MS call to the PSTN. Consequently, sometimes the home MSC and Gateway MSC functions are served by the same entity, but other times they are not (such as when the MS is roaming). Typically, a Visiting Location Register (“VLR”) 116 is co-located with the MSC 110 and a logically singular HLR is used in the mobile network (a logically singular HLR may be physically distributed but is treated as a single entity). As will be explained below, the HLR and VLR are used for storing subscriber information and profiles.
Radio channels 112 are associated with the entire coverage area. The radio channels are partitioned into groups of channels allocated to individual cells. The channels are used to carry signaling information to establish call connections and related arrangements, and to carry voice or data information once a call connection is established.
Mobile network signaling involves at least two main aspects. One aspect involves the signaling between an MS and the rest of the network. In the case of 2G (“2G” is the industry term used for “second generation”) and later technology, this signaling concerns access methods used by the MS (such as time-division multiple access, or TDMA; code-division multiple access, or CDMA), pertaining to, for example, assignment of radio channels and authentication. A second aspect involves the signaling among the various entities in the mobile network, such as the signaling among the MSCs, BSCs, VLRs, and HLRs. This second part is sometimes referred to as the Mobile Application Part (“MAP”) especially when used in the context of Signaling System No. 7 (“SS7”). SS7 is a common channel signaling system by which elements of the telephone network exchange information, in the form of messages.
The various forms of signaling (as well as the data and voice communication) are transmitted and received in accordance with various standards. For example, the Electronics Industries Association (“EIA”) and Telecommunications Industry Association (“TIA”) help define many U.S. standards, such as IS-41, which is a MAP standard. Analogously, the CCITT and ITU help define international standards, such as GSM-MAP, which is an international MAP standard. Information about these standards is well known and may be found from the relevant organizing bodies as well as in the literature, see, e.g., Bosse, SIGNALING IN TELECOMMUNICATIONS NETWORKS (Wiley 1998).
To deliver a call from an MS 114 , a user dials the number and presses “send” on a cell phone or other MS. The MS 114 sends the dialed number indicating the service requested to the MSC 110 via the BS 107 . The MSC 110 checks with an associated VLR 116 (described below) to determine if the MS 114 is allowed the requested service. The Gateway MSC routes the call to the local exchange of the dialed user on the PSTN 120 . The local exchange alerts the called user terminal, and an answer back signal is routed back to the MS 114 through the serving MSC 110 which then completes the speech path to the MS. Once the setup is completed the call may proceed.
To deliver a call to an MS 114 , (assuming that the call originates from the PSTN 120 ) the PSTN user dials the MS's associated phone number. At least according to U.S. standards, the PSTN 120 routes the call to the MS's home MSC (which may or may not be the one serving the MS). The MSC then interrogates the HLR 118 to determine which MSC is currently serving the MS. This also acts to inform the serving MSC that a call is forthcoming. The home MSC then routes the call to the serving MSC. The serving MSC pages the MS via the appropriate BS. The MS responds and the appropriate signaling links are setup.
During a call, the BS 107 and MS 114 may cooperate to change channels or BTSs 102 , if needed, for example, because of signal conditions. These changes are known as “handoffs,” and they involve their own types of known messages and signaling.
One aspect of MAP involves “mobility management.” Different BSs and MSCs may be needed and used to serve an MS, as the MS 114 roams to different locations. Mobility management helps to ensure that the Gateway MSC has the subscriber profile and other information the MSC needs to service (and bill) calls correctly. To this end, MSCs use VLR 116 and HLR 118 . The HLR is used to store and retrieve the mobile identification number (“MIN”), the electronic serial number (“ESN”), MS status, and the MS service profile, among other things. The VLR stores similar information in addition to storing an MSC identification that identifies the Gateway (Home) MSC. In addition, under appropriate MAP protocols, location update procedures (or registration notifications) are performed so that the home MSC of a Mobile Subscriber can locate its users. These procedures are used when an MS roams from one location to another or when an MS is powered on and registers itself to access the network. For example, a location update procedure may proceed with the MS 114 sending a location update request to the VLR 116 via the BS 107 and MSC 110 . The VLR 116 sends a location update message to the HLR 118 serving the MS 114 , and the subscriber profile is downloaded from the HLR 118 to the VLR 116 . The MS 114 is sent an acknowledgement of a successful location update. The HLR 118 requests the VLR (if any) that previously held profile data to delete the data related to the relocated MS 114 .
FIG. 2 shows in more detail the signaling and user traffic interfaces between a BS 107 and an MSC 110 in a CDMA mobile network. The BS 107 communicates signaling information using an SS7-based interface for controlling voice and data circuits known as the “A1” interface. An interface known as “A2” carries user traffic (such as voice signals) between the switch component 204 of the MSC and the BS 107 . An interface known as “A5” is used to provide a path for user traffic for circuit-switched data calls (as opposed to voice calls) between the source BS and the MSC. Information about one or more of A1, A2, A5 may be found in CDMA Internetworking-Deploying the Open-A Interface, Su-Lin Low, Ron Schneider, Prentice Hall, 2000, ISBN 0-13-088922-9.
With reference to FIG. 3 , wireless services include data services such as “packet data calls” between the MS and the Internet, such as data calls in accordance with the CDMA 2000 standard. In the case of an MS known as a 3G device, a data call from the MS is routed from a 3G-capable BSC to a mechanism known as a Packet Data Serving Node (PDSN). The PDSN interfaces between the transmission of the data in the fixed network and the transmission of the data over the air interface. The PDSN interfaces to the BS through a Packet Control Function (PCF), which may or may not be co-located with the BS.
A wireless packet R-P interface is provided between PCF and PDSN and implements protocol conversation between the wireless channel and the wire channel. The R-P interface is based on “A10” and “A11” aspects of the A interface, as described in 3rd Generation Partnership Project 2 “3GPP2”-3GPP2.A-S0001-0.1 June 2000. The A10 interface (also known as a GRE tunnel) provides a data transport protocol between the PCF and the PDSN. The A11 interface provides control signaling for data flow between a PCF and a PDSN.
Two modes of operation are typically offered by a PDSN: Simple IP and Mobile IP. Simple IP refers to a service in which the MS is assigned a dynamic IP address from the local PDSN, and is provided IP routing service to a visited access provider network. The MS may maintain its IP address as long as it is served by a radio network which has connectivity to the address assigning PDSN. There is no IP address mobility beyond this PDSN.
In particular, when a Simple IP Mobile Subscriber (MS) moves between areas served by different PCFs, that subscriber may be directed to a new PDSN. The new PDSN mandates renegotiation of all Point to Point Protocol (PPP) parameters (such as the IP address assigned to the MS) since it is unaware of the previous PPP session state. The renegotiation process is highly disruptive to data applications that may be running on the MS, often requiring the applications to terminate service. For Simple IP Mobile Subscribers, since there is no provision for a PDSN to PDSN handoff during a data call, IP connectivity cannot be maintained.
Mobile IP provides an IP layer mobility management function that maintains existing communications across PDSNs. Mobile IP requires that special capabilities be built into Mobile Subscribers. For Mobile IP Mobile Subscribers, in order to maintain IP connectivity, the Mobile Subscriber effects a PDSN to PDSN handoff by registering with its Home Agent in accordance with a well known protocol document RFC2002 (http://www.ietf.org/rfc/rfc2002.txt?number=2002). In this case, a new packet data session is established along with the PPP session. In the mobile IP model, the handoff is less disruptive, as network-layer (IP) parameters are not renegotiated. However, there can be significant delay in reestablishing a mobile IP tunnel between the PDSN Foreign Agent (FA) and the Home Agent (HA) for that user. This delay is disruptive to packets in transit to the MS. There is no similar IP layer mobility management function support between PDSNs for Simple IP service.
In Simple IP, the PDSN terminates the A10/A11 data stream and either provides a PPP tunneling service such as L2TP on the PPP payload contained within the user's A10 data stream, or it terminates the user's PPP data stream and forwards the resulting user's IP packets into a virtual private network (VPN) IP cloud corresponding to that subscriber. In the Mobile IP mode, the PDSN incorporates the Foreign Agent function described in document RFC2002. The Home Agent function described in the document is served by another device within the IP cloud.
The PCF initiates setup of an A10 connection by sending an A11-Registration Request message to a selected PDSN. (The PCF initially selects a PDSN via a mechanism that is specific to the PCF implementation. Typically, the PCF has a statically configured prioritized list of PDSN addresses.) If the selected PDSN does not accept the connection, it returns an A11-Registration Reply with a reject result code. The PDSN may return an A11-Registration Reply message with result code ‘88H’ (Registration Denied—unknown PDSN address). When code ‘88H’ (the same as ‘136’ decimal) is used, an alternate PDSN address is included in the A11-Registration Reply message. The address of the alternate proposed PDSN is returned in the Home Agent field of the A11-Registration Reply message. On receipt of an A11-Registration Reply with code ‘88H’, the PCF initiates establishment of the A10 connection with the alternate proposed PDSN by sending a new A11-Registration Request message to the alternate proposed PDSN.
A load balancing technique has been proposed in which multiple PDSNs are linked to a primary PDSN. The primary PDSN keeps track of the data call loads being handled by the other PDSNs. All A11-Registration Request messages from the PCF are received by the primary PDSN, which then uses the A11-Registration Reply message with result code ‘88H’ to redirect the PCF to one of the other PDSNs in accordance with load balancing principles. If the MS roams to an area corresponding to a different PCF, that PCF sends a new A11-Registration Request to the primary PDSN, which may cause the MS to be associated with a different PDSN, with disruptive consequences as described above.
SUMMARY
Data interconnections are managed in a mobile communications network having multiple packet control function entities (PCFs) and multiple packet data serving nodes (PDSNs), wherein each PCF and PDSN communicates signaling messages according to a mobile signaling protocol. In an aspect of the invention, information for a Mobile Subscriber (MS) is received, and the MS is associated with a same one of the PDSNs when the MS moves from a first area covered by a first PCF to a second area covered by a second PCF.
In another aspect of the invention, it is determined that a first PCF has issued a first connection request on behalf of an MS. As a result of the first connection request, a selection protocol is executed a first time to select a PDSN that corresponds to the MS. It is determined that a second PCF has issued a second connection request on behalf of the MS. The selection protocol is executed a second time to select the same PDSN that was selected as a result of the first connection request.
In another aspect of the invention, a list of the PDSNs is maintained. A hashing protocol is executed to map a number derived from an MS identification number onto the list of PDSNs. A result is derived from the mapping. The result is included in a response to a connection request from one of the PCFs.
In another aspect of the invention, it is determined that a first one of the PCFs has issued a first connection request on behalf of a Mobile Subscriber (MS), and, by an entity other than one of the PCFs or one of the PDSNs, it is determined whether to execute a selection protocol to select, from among the PDSNs, a PDSN that corresponds to the MS.
In another aspect of the invention, it is determined that one of the PCFs has issued a connection request on behalf of a Mobile Subscriber (MS), and a response is caused to be issued back to the PCF directing the PCF to issue a connection request to a service address of one of the PDSNs, the one of the PDSNs also having a redirection address.
Implementations of the invention may provide one or more of the following advantages. During a data call, inter-PDSN handoffs can be reduced or avoided. A PPP connection between a Mobile Subscriber (such as a mobile handset) and a PDSN can be maintained when the Mobile Subscriber roams outside an area covered by one BSC or PCF and into an area covered by another BSC or PCF. Accordingly, with respect to applications that depend on the maintenance of the PPP connection, disruptions can be reduced or eliminated. The PPP connection can be maintained regardless of whether the Mobile Subscriber is compatible with mobile IP. Applications that are compatible with Simple IP and standard handsets can maintain data call integrity even when the Mobile Subscriber roams among areas covered by different BSCs or PCFs. With mobile IP, interface PDSN handoffs can be reduced or eliminated, which helps to reduce handoff latency. Each PDSN can redirect calls to other PDSNs properly without tracking the calls being handled by the other PDSNs.
Other advantages and features will become apparent from the following description, including the drawings, and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1–3 are illustrations of a prior art mobile communications system.
FIG. 4 is a block diagram of elements of a system for managing packet data interconnections.
FIGS. 5–8 are flow diagrams of procedures executable by one or more of the systems of FIGS. 1–4 .
DETAILED DESCRIPTION
A method and a system are provided for managing packet data interconnections in mobile communications. The method and system help to avoid a PDSN handoff in MS data communications when an MS moves between areas associated with different PCFs.
In a first general approach, each MS has a permanently assigned PDSN. The PCF obtains this address (and backup addresses) from the Home Location Register (HLR) for a Mobile Subscriber when the subscriber registers and authenticates with the network. In such a case, all of the network providers interconnect the IP radio networks between all PCFs and PDSNs regardless of geographical or administrative concerns/boundaries. Changes are made to the HLR and to the messaging between the BSC/MSC (HLR proxy) and the PCF. A static mapping between Mobile Subscribers and available PDSNs is maintained. The HLR may also identify a backup PDSN address for each MS in case the primary PDSN for an MS is not available.
In a second general approach, an administratively cooperative group of PCFs use a signaling scheme among themselves to identify an appropriate PDSN to service each A10/A11 Mobile Subscriber session. A large amount of per session storage and complex signaling is involved; each PCF is aware of every currently established MS session within an administrative domain. In a simplification, each PCF within an administrative domain is configured with a complete list of available PDSNs and each PCF applies the same or effectively the same hashing function that maps mobile session identification information onto the list of PDSNs. Information that may be used to identify a potential mobile session includes the following “three number set”: MN Type, MN ID, and MN Session Reference ID. In a specific implementation, each PCF selects the primary PDSN to terminate a MS session by hashing the three number set onto the list of PDSNs and first offering the session to the selected PDSN; if the session is not accepted by the selected primary PDSN, any other available PDSN can be used (the PCF may give a preference to a PDSN suggested by the original PDSN that did not accept the offered session). In such a case, non-overlapping administrative PCF areas are defined, and it may be necessary to address how to handle taking PDSNs in and out of service, and how to handle dynamic load balancing with a lack of feedback from PDSNs. An inter-PCF signaling protocol may be used, or new PCF-PDSN signaling messages may be provided so that the PCF has access to information available only within the PDSN, such as user profile and PDSN administrative state information, which may be needed or helpful.
In a third general approach, described in more detail below, existing capabilities of PCFs are used by enhanced PDSN software to allow the PDSN software to help avoid inter-PDSN handoffs. In particular, in a specific implementation, the R-P Registration Request Error code 0x 88 (indicating “Registration Denied==administratively denied”), is used by the enhanced PDSN software to help avoid PDSN handoffs. When this error code is returned by the PDSN in response to the PCF issuing a registration request, the PDSN may suggest another PDSN to try instead of itself. Using this mechanism, the PDSN can suggest a specific PDSN to terminate a session for a Mobile Subscriber. A variety of techniques are described below for selecting a specific PDSN to suggest to a PCF performing a registration request. The techniques allow an ongoing data call that has changed PCFs to continue to be directed to the same PDSN, which helps to avoid PDSN handoffs.
A first technique for selecting a specific PDSN to suggest to a PCF includes configuring each PDSN with two addresses (also known as ports): an R-P redirection address and an R-P service address. The PCFs are configured only with the addresses that correspond to R-P redirection addresses. When a PCF contacts the PDSN for the first time, the PDSN selects the specific PDSN to handle the new session for the Mobile Subscriber based on the three number set (MN Type, MN ID, and MN Session Reference ID). The three numbers are used in a PDSN selection procedure to select an “optimal” PDSN. The PDSN selection procedure may be or include a hashing function to a preconfigured (or discovered) list of PDSN service addresses. An example follows:
Two PDSNs are provided:
PDSN-A, configured with service address 10.1.1.11 and with redirection address 10.1.1.2 PDSN-B, configured with service address 10.2.2.1 and with redirection address 10.2.2.2
Both PDSNs are configured with a PDSN service address list as follows: (10.1.1.1, 10.2.2.1). Both PDSNs are provided with a hashing function:
H(mn-type,mn-id,mn-session-id)=(mn-type+nm-id+nm-session-id) mod 2
The hashing function computes an index into the PDSN service address list (an index of 0 corresponds to 10.1.1.1; an index of 1 corresponds to 10.2.2.1).
A PCF is configured with the following list of PDSN addresses: (10.1.1.2, 10.2.2.2).
A call for MS #1 comes in, having the following characteristics:
MN-TYPE=1 MN ID=978851110 MN Session Reference ID=1
The PCF sends an R-P registration request to the first PDSN in its list: PDSN-A (10.1.1.2). PDSN-A computes H(1,978851110,1)=0, which indicates that the service address for the call is to be 10.1.1.1. The service address 10.1.1.1 represents PDSN-A itself, which therefore accepts the call.
A call for MS #2 comes in, having the following characteristics:
MN-TYPE=1 MN ID=978851111 MN Session Reference ID=1
The PCF sends an R-P registration request to the first PDSN in its list: PDSN-A (10.1.1.2). PDSN-A computes H(1,978851111,1)=1, which indicates that the service address for the call is to be 10.2.2.1. Since the service address 10.2.2.1 does not correspond to PDSN-A, a registration reject message with error code 0×88 is sent back to the PCF with the Home Agent field of the message set to 10.2.2.1. The PCF sends a new registration request to PDSN-B 10.2.2.1. Since the request is sent to the service address, PDSN-B does not execute the hashing function; instead, PDSN-B starts R-P service if sufficient resources are available.
An example procedure is illustrated in FIGS. 4–5 . (For simplicity, FIG. 4 does not show the elements between the MS and the PCF shown in FIG. 3 .) Each of PDSNs PDSN1, PDSN2, PDSN3, PDSN4 has an R-P redirection address and an R-P service address (such as, in the case of PDSN1, address A and address B, respectively). PCF1 and PCF2 are configured to use only the R-P redirection addresses for initial contact with the PDSNs. Each PDSN runs software SW that operates as now described. Initially, MS is in an area covered by PCF1. When a data call involving MS is initiated, PDSN1 receives a connection request (an A11-Registration Request message) from PCF1 at PDSN1 address A (step 1010 ). The PDSN corresponding to MS (PDSN2 in this example) is determined (step 1020 ). If the PDSN corresponding to MS is the current PDSN (in this example, if the corresponding PDSN were PDSN1), the connection request is accepted and the procedure ends (step 1030 ). A response (an A11-Registration Reply with a reject result code ‘88H’) is transmitted to PCF1 indicating the R-P service address (here, address D) of the corresponding PDSN. (step 1040 ).
If MS roams to the area served by PCF2, PCF2 sends a connection request to one of the PDSNs (here, PDSN4, at address G). Software SW on PDSN4 determines, as the same software SW on PDSN1 did above, that the PDSN corresponding to MS is PDSN2, and responds to PCF2 indicating a redirection to address D of PDSN2. Thus, MS remains associated with PDSN2 despite having moved from an area served by PCF1 to an area served by PCF2.
In at least two ways, the arrangement described above helps to reduce or prevent unnecessary redirection communications between the PCFs and the PDSNs. First, by accepting a connection request when the PDSN corresponding to MS is the current PDSN, the software SW avoids causing the PCF to redirect the request back to the same PDSN. Second, by providing for separate redirection and service addresses on each PDSN, the software SW can be enhanced to detect when a request is the result of a redirection, and thereby avoid causing the PCF to perform another redirection, back to the same PDSN. According to the enhancement, since the PCFs are configured with the redirection addresses only, when a request comes into the PDSN via the service address instead of the redirection address, the software SW accepts the request without further analysis, because it is assumed that the PCF generates a request to the service address only as a result of a redirection response.
An alternative PDSN selection procedure includes dynamic management of the key-space generated by the hashing function. The following is a description of a procedure 6000 ( FIG. 6 ) suitable for the dynamic management of key space. A key space may consist of a finite integral range 0.N. This key space may correspond directly to the three number set (MN Type, MN ID, and MN Session Reference ID) or to the result of a hash function applied to the three number set. First, the PDSNs within a domain are directed to discover each other (step 6010 ) and agree on membership to the administrative PDSN domain (step 6020 ). Next, the key space is evenly partitioned among the operationally active PDSNs within the administrative domain (step 6030 ), keeping intact any active sessions. Each PDSN maintains a complete view of the partitioned key space (step 6040 ) and attempts to minimize or reduce the number of holes in the space (step 6050 ) by acquiring key space from peers as sessions are added locally. An example follows:
Two PDSNs are provided:
PDSN-A, configured with service address 10.1.1.1 and with redirection address 10.1.1.2. PDSN-B, configured with service address 10.2.2.1 and with redirection address 10.2.2.2.
Both PDSNs are configured with an available PDSN service address list (10.1.1.1, 10.2.2.1), a PDSN service list having 65536 entries (10.1.1.1 <repeats 32768 times>, 10.2.2.1 <repeats 32768 times>), and a hashing function
H(mn-type,mn-id,mn-session-id)=(mn-type+nm-id+nm-session-id) mod 65536.
The hashing function computes an index into the 65536 entry PDSN service list.
To join the existing two PDSNs, another PDSN solicits a list of free entries from each PDSN, intersects the lists, and asserts ownership of unused slots by sending an request ownership message to each PDSN. After receiving a positive acknowledgement from each PDSN, the other PDSN may send an assert ownership message to each PDSN.
As PDSNs are added or removed or added and removed, and as load changes, it may be necessary or helpful to re-partition the key space dynamically among the PDSNs. In a specific implementation, such re-partitioning is performed in a centralized fashion by a procedure 7000 ( FIG. 7 ) as follows. A designated “master” PDSN is directed to propose various repartitions of the key space (step 7010 ). In such a case, each PDSN informs the master PDSN how many key conflicts the PDSN would have with a proposed partition (step 7020 ) and, depending on the circumstances, the master PDSN proposes further refinements of the key space (step 7030 ) by further splitting contentious key ranges. When an acceptable repartition of the key space is reached, each PDSN switches to the new key space (step 7040 ). It is desirable to avoid unresolved key conflicts, which may result in failure to achieve transparent inter-PDSN mobility in the simple IP case.
A second technique for selecting a specific PDSN to suggest to a PCF shares some aspects with the first technique. In this case, according to a procedure 8000 ( FIG. 8 ), an external server such as a Remote Authentication Dial-In User Service (RADIUS) server is used to select an “optimal” PDSN to handle an R-P session (step 8010 ), and return the “optimal” PDSN selection back to the PCF (step 8020 ). An advantage is that this technique takes advantage of the existing radio resource records that identify the last PDSN that handled a session corresponding to a particular three number set (MN Type, MN ID, and MN Session Reference ID). An external server may also provide load balancing services or map specific users to specific PDSNs.
The technique (including one or more of the procedures described above) may be implemented in hardware or software, or a combination of both. In at least some cases, it is advantageous if the technique is implemented in computer programs executing on one or more programmable computers, such as a line-card or a control processor of a PDSN or a PCF, or a RADIUS server, HLR, or VLR running on a general purpose computer, or a computer running or able to run Microsoft Windows 95, 98, 2000, Millennium Edition, NT, XP; Unix; Linux; or MacOS; that each include a processor such as an Intel Pentium 4, a storage medium readable by the processor (including volatile and non-volatile memory and/or storage elements), at least one input device such as a keyboard, and at least one output device. Program code is applied to data entered using the input device to perform the method described above and to generate output information. The output information is applied to one or more output devices such as a display screen of the computer.
In at least some cases, it is advantageous if each program is implemented in a high level procedural or object-oriented programming language such as C, C++, Java, or Perl to communicate with a computer system. However, the programs can be implemented in assembly or machine language, if desired. In any case, the language may be a compiled or interpreted language.
In at least some cases, it is advantageous if each such computer program is stored on a storage medium or device, such as ROM or magnetic diskette, that is readable by a general or special purpose programmable computer for configuring and operating the computer when the storage medium or device is read by the computer to perform the procedures described in this document. The system may also be considered to be implemented as a computer-readable storage medium, configured with a computer program, where the storage medium so configured causes a computer to operate in a specific and predefined manner.
Other embodiments are within the scope of the following claims. For example, one or more of the actions performed by the software SW may be performed by another entity, such as the PCF or the MSC. In such a case, the other entity may determine the PDSN corresponding to the MS.
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Data interconnections are managed in a mobile communications network having multiple packet control function entities (PCFs) and multiple packet data serving nodes (PDSNs), wherein each PCF and PDSN communicates signaling messages according to a mobile signaling protocol. Information for a Mobile Subscriber (MS) is received. The MS is associated with a same one of the PDSNs when the MS moves from a first area covered by a first PCF to a second area covered by a second PCF. It is determined that a first PCF has issued a first connection request on behalf of an MS. As a result of the first connection request, a selection protocol is executed a first time to select a PDSN that corresponds to the MS. It is determined that a second PCF has issued a second connection request on behalf of the MS. The selection protocol is executed a second time to select the same PDSN that was selected as a result of the first connection request.
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FIELD OF THE INVENTION
[0001] This invention relates generally to vehicle hitches and, more specifically, to an improved receiver style hitch in a winch mounting system and a method of using the same.
BACKGROUND OF THE INVENTION
[0002] A typical vehicle mounting system includes a hitch which attaches directly to the vehicle to provide a connection between the vehicle and a trailer or other attachment. The hitch may be factory installed on original bumpers or frames or may be welded or bolted onto bumpers or vehicle frames after market. It is helpful to have hitches on both the front and rear of the vehicle for versatility. A hitch may be a weight carrying hitch or may include a weight distribution system that enhances handling and braking and increases capacity beyond what is recommended when a weight-carrying hitch is used.
[0003] A standard receiver style hitch has one receiver. The standard receiver style hitch includes a main cross tube with the one receiver in the center thereof in a direction perpendicular to the main cross tube. The receiver is the receptacle part of the hitch which accommodates inserts. A common receiver style hitch is a square tube hitch with a two inch square receptacle for receiving inserts, although round tube hitches and other receiver sizes are available. The receiver is typically about seven inches long. An insert is any item that slides into the receptacle of a receiver style hitch. Exemplary inserts include drawbars, ball mounts, bike racks, winch carriers, etc.
[0004] The main cross tube may include mounting plates or the like to permit mounting the hitch to the bumper or frame of the vehicle using bolts. The hitch may also, in some circumstances, be welded to the bumper or fame of the vehicle. The hitch may be mounted in a manner that the main cross tube extends across the horizontal axis of the car at the front or rear of the vehicle with the receiver projecting away from the vehicle to permit sliding the insert into the receiver of the hitch. The receiver projects out from the center of the front or rear of the vehicle. A hitch pin or clip may be used to fasten the insert into the hitch.
[0005] As is known in the art, a winch carrier may be fastened into the hitch for a winch mounting system. A winch carrier is used to carry a winch on the vehicle. When the winch is mounted on the winch carrier, it is referred to herein as a “winch and carrier assembly.” Winches have been commonly used for moving objects and vehicles. In the typical application, one end of a wire rope is securely attached to a stationary object while the other end is wound around the drum of a winch. Of course, it is to be appreciated that the winch may also be secured to the stationary object with the winch rope securely attached to the object to be moved.
[0006] The standard portable winch carrier includes a cradle with a pair of handles at shoulder width apart to make it easy to carry the winch from one hitch to another. A shank extends from the center of the winch carrier and is received and fastened into the receptacle of the standard receiver hitch. The winch carrier may be removed from the vehicle or storage area and lifted using the cradle handles and plugged into the hitch as per conventional installation. This permits operating the winch anytime and anywhere and also permits moving the winch from one vehicle to another if both vehicles are equipped with receiver style hitches.
[0007] Conventional hitches, especially when used with a winch and carrier assembly, face the most extreme demands and must withstand the stress encountered in a particular situation. A winch mounting system must distribute the rated load of the winch along the vehicle frame i.e. they are designed to the vehicle's capabilities to withstand straight pulls, as well as side loads. This minimizes the possibility of changing the alignment of the vehicle, affecting its ride and handling. In addition, braking may be affected and capacity limited by hitch selection.
[0008] There is therefore a need for an improved receiver-style hitch that may be used with a variety and plurality of inserts and that reduces stress on common failure points of the standard receiver-style hitch. There is a further need for an improved receiver-style hitch that may be used in a winch mounting system that provides better ride, handling and braking and that can support full-size rigs and heavier recovery situations and enables carrying a winch on either end of a vehicle. There is also a need for an improved receiver hitch that may be used in a winch mounting system that positions the winch for optimum performance. There is a further need for an improved receiver style hitch that may be used in a winch mounting system and method whereby the winch and carrier assembly may be easily and quickly installed and removed by one person. There is an additional need for an improved receiver style hitch that may be used in a winch mounting system and method that has a strong and stable mounting platform. The present invention fulfills these needs and provides other related advantages.
SUMMARY OF THE INVENTION
[0009] The present invention resides in an improved winch mounting system. The improved winch mounting system comprises, generally, a receiver hitch having a plurality of receivers and a winch carrier slidably mounted therein.
[0010] In one preferred form of the invention for a winch mounting system for the rear end of a vehicle, the receiver hitch includes a substantially straight main cross tube terminating at both ends with side mounting brackets that may be mounted to the vehicle frame. The plurality of receivers includes a middle receiver in a substantially central position with respect to the side mounting brackets and between and spaced apart from a pair of outer receivers. The middle receiver extends in a perpendicular direction from one side of the receiver hitch. The pair of outer receivers also extends in a perpendicular direction from the same side of the receiver hitch and may be spaced at about equal distances apart from the middle receiver at an off-center position with respect to the main cross tube. The outer receivers may be longer than the inside middle receiver. The winch carrier may be slidably mounted into the open ends of the outer receivers and fastened by a hitch pin or the like.
[0011] The winch carrier includes a cradle having a pair of handles and a face plate mounted on the front thereof. A pair of shanks extending behind the face plate is received in the outer receivers. As is known in the art, a winch may be mounted into the winch carrier for a “winch and carrier assembly.” The winch and carrier assembly may also include a conventional fairlead or cable guide assembly means for guiding the winch rope and thereby minimizing damage to the winch rope.
[0012] In another form of the invention for the front end of the vehicle, a front receiver hitch includes a substantially straight cross bar with downwardly sloping ends terminating at about a 90 degree angle in hitch mounting plates. The front receiver hitch includes a pair of spaced apart receivers in a substantially off-center position with respect to the hitch mounting plates. The winch and carrier assembly is removably mounted to the front hitch in the same manner as with the rear hitch i.e. by slidably mounting the winch carrier shanks into the receivers and inserting the hitch pin through aligned opposite paired openings. In another embodiment, the front receiver hitch may further include shackles mounted to a front face of the hitch mounting plates.
[0013] The receiver style hitch may be used with other inserts slidably mounted into one or more of the receivers. For example, one or more ball mounts (not shown) and/or one or more clevis mounts, etc. may be inserted in the receivers.
[0014] Other features and advantages of the present invention will become apparent from the following more 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
[0015] The accompanying drawings illustrate the invention. In such drawings:
[0016] FIG. 1 is a perspective assembly view of a winch mounting system embodying the invention, illustrating a winch carrier having a pair of rearwardly-extending shanks being inserted into corresponding receivers of a receiver style hitch;
[0017] FIG. 1A is a perspective view of the winch carrier, illustrating a face plate mounted on the front of the winch carrier and having a slot therein;
[0018] FIG. 1B is a front view of a winch and carrier assembly, illustrating a winch mounted on the winch carrier with its wire rope fed through the slot of the face plate and through a roller fairlead mounted to the front of the winch and carrier assembly;
[0019] FIG. 2 is a top view of the winch and carrier assembly of FIG. 1B , illustrating the wire rope wrapped around a winch drum and extending exteriorly from the winch;
[0020] FIG. 2A is a side view of the winch and carrier assembly of FIGS. 1B and 2 ;
[0021] FIG. 2B is a side perspective view of the winch and carrier assembly of FIGS. 1B, 2 , and 2 A slidably mounted into the receiver-style hitch mounted to the rear of a vehicle;
[0022] FIG. 3 is a perspective view of an alternative embodiment of a receiver-style hitch mounted to the front of a vehicle with mounting plates;
[0023] FIG. 3A is a perspective assembly view of the front mounted hitch of FIG. 3 receiving the winch and carrier assembly of FIGS. 1B-2A ;
[0024] FIG. 3B is an alternative embodiment of the front mounted hitch of FIG. 3 , illustrating a shackle on each of the mounting plates for the front mounted receiver;
[0025] FIG. 3C is a side view of one side of the front mounted hitch of FIG. 3B ; and
[0026] FIG. 3D is a perspective side view of the front mounted hitch of FIGS. 3B and 3C receiving the winch and carrier assembly of FIGS. 1B-2A .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] As shown in the drawings for purposes of illustration, the present invention as shown in FIGS. 1-2B is concerned with an improved winch mounting system, generally designated in the accompanying drawings by the reference number 10 . The improved winch mounting system comprises, generally, a receiver hitch 12 having a pair of outer receivers 14 ; and a winch carrier 16 slidably mounted into the pair of outer receivers 14 . The receiver hitch 12 may also include a middle receiver 18 between the pair of outer receivers 14 . The receiver hitch 12 may be used with inserts other than the winch carrier 16 as hereinafter described.
[0028] In the first embodiment as shown in FIG. 1 , the improved receiver hitch 12 includes a substantially straight square main cross tube 20 terminating at both, ends with side mounting brackets 21 with the middle receiver 18 in a substantially central position with respect to the side mounting brackets 21 . As is known in the art and as shown in FIG. 1 , the middle receiver 18 extends in a perpendicular direction from one side of the receiver hitch 12 . The pair of outer receivers 14 also extends in a perpendicular direction from the same side of the receiver hitch 12 and may be spaced at about equal distances apart from the middle receiver 18 at an off-center position with respect to the main cross tube 20 . The outer receivers 14 may be longer than the middle receiver 18 . The pair of outer receivers 14 measure about 12.5 inches long and therefore extend about 4.5 inches beyond the standard eight inch middle receiver. The additional and deeper receivers allow for more weight transfer to the hitch, cross tube, side brackets and vehicle frame helping the hitch able to withstand heavier loads.
[0029] Each of the outer and middle receivers 14 and 18 has a first end and a second end 22 and 24 . The first end 22 may be mounted by welding or the like to the one side of the main cross tube 20 . The receiver hitch 12 may be an OEM or an aftermarket hitch. An aftermarket hitch may include a standard receiver-style hitch with one standard middle receiver to which the pair of outer receivers 14 may be added by welding or the like. The second end 24 of the receivers is the receptacle end for receiving the inserts. Opposite paired openings 26 in both sides of the receiver near the second end 24 are for purposes as described hereinafter. Although a square tube hitch is shown, it is to be appreciated that a round tube hitch may also be used.
[0030] The side mounting brackets 21 include attachment openings 28 through which fasteners (not shown) may be used to mount the main cross tube 20 to the frame or bumper at the rear of the vehicle as shown in FIG. 2B . Although side mounting brackets 21 are shown in the drawing, it is to be appreciated that the particular mounting brackets used will depend on the installation instructions and the type of vehicle to which the hitch is mounted.
[0031] The winch carrier 16 shown in FIGS. 1 and 1 A includes a cradle 30 having a pair of handles 32 and a face plate 34 mounted on the front thereof. The face plate 34 includes a front side and a rear side 36 and 38 and a slot 40 therein for purposes as described hereinafter. A pair of shanks 42 extends rearwardly from the bottom of the rear side of the face plate in a perpendicular direction to and under the cradle 30 . The pair of shanks 42 is slightly smaller in outside dimension than the inside dimension of the outer receivers 14 in order to be inserted therein. As shown in FIG. 2B , the pair of shanks 42 may be received in the corresponding pair of outer receivers 14 . The shanks 42 include opposite paired openings 44 in the sides thereof just rearwardly of the cradle 30 for purposes as described hereinafter. The positioning of the opposite paired openings 44 in the shanks 42 is to space the winch carrier 16 away from the vehicle when the winch carrier is slidably mounted into the receiver hitch as shown in FIG. 2B . The opposite paired openings 44 in the shanks 42 are positioned to hold the cradle 30 about nine inches out from the vehicle.
[0032] As is known in the art and as shown in FIGS. 1B, 2 , 2 A and 2 B, a winch 46 including a drum 48 for winding a wire rope 50 and a motor 52 which rotates the drum 48 may be mounted into the cradle 30 behind the rear side 38 of the face plate 34 . The winch 46 further includes a control box 54 and clutch 56 as shown. When the winch is mounted on the cradle 30 of the winch carrier 16 , it is referred to herein as a “winch and carrier assembly”. The wire rope 50 from the winch passes through the slot 40 in the face plate 34 .
[0033] As shown in FIGS. 1B, 2A and 2 B, the winch and carrier assembly may also include a conventional fairlead 58 or cable guide assembly means for guiding the wire rope 50 and thereby minimizing damage to the wire rope. The fairlead 58 surrounds the slot 40 in the face plate 34 and provides rollers for guiding the wire rope 50 onto and off of the winch drum 48 . The fairlead 58 may be fixedly coupled by bolts to the front side 36 of the face plate 34 and into the winch 46 as shown in FIGS. 2A and 2B .
[0034] As shown in FIG. 2B , the winch carrier 16 may be slidably mounted into the pair of outer receivers 14 of the hitch until the opposite paired openings 26 and 44 in each of the pair of outer receivers 14 and the winch carrier shanks 42 are substantially aligned. The winch carrier 16 may be fastened to the hitch by inserting the hitch pin or clip (not shown) through the substantially aligned opposite paired openings 26 and 44 . When so fastened, the combination of the hitch and winch carrier 16 are referred to herein as a winch mounting system.
[0035] In an alternative embodiment as shown in FIGS. 3-3A , a front receiver hitch 60 includes a substantially straight main cross tube 62 with downwardly sloping ends terminating at about a 90 degree angle in hitch mounting plates 64 . The front receiver hitch 60 may be bolted to the frame of the vehicle as shown in FIGS. 3 and 3 A. It is to be appreciated that the front receiver hitch may in some applications be installed on the bumper of a vehicle. The hitch mounting plates 64 include attachment openings (not shown) for mounting bolts 66 . The front receiver hitch 60 includes a pair of spaced apart outer receivers 68 in a substantially off-center position with respect to the hitch mounting plates 64 . The outer receivers 68 include opposite paired openings 69 near the receptacle end. The outer receivers may be shorter than those previously described. The winch carrier 16 as shown in FIG. 1A or the winch and carrier assembly as shown in FIG. 3A may be removably mounted to the front receiver hitch 60 in the same manner as with the rear hitch i.e. by slidably mounting the winch carrier shanks into the receivers and inserting the hitch pin or clip (not shown) through the substantially aligned opposite paired openings.
[0036] Although a three receiver hitch on the rear end of the vehicle and a two receiver hitch on the front end of the vehicle has been described and shown, it is to be appreciated that substantial benefit may be derived from an alternative configuration of the invention whereby the three receiver hitch is mounted on the front of the vehicle and the two receiver hitch is mounted on the rear end of the vehicle.
[0037] In another embodiment as shown in FIGS. 3B-3D , the front receiver hitch 60 may further include shackles 70 mounted to a front face of the hitch mounting plates 64 as shown in FIG. 3B . The shackles project downwardly and forwardly as shown in FIGS. 3C and 3D . The shackles may be used as additional bracing for side pulls or for use to strap the winch to a rock or tree for vehicle-free winching or for other known purposes.
[0038] Although the receiver hitches have been described for use in a winch mounting system, it is to be appreciated that the receiver style hitch may be used with other inserts slidably mounted into one or more of the receivers. For example, one or more ball mounts (not shown) and/or one or more clevis mounts, etc. may be inserted into the receivers.
[0039] In operation, the receiver hitches of the present invention may be mounted to the vehicle by methods well known in the art. The winch and carrier assembly may be moved from the front or rear of the vehicle if there are front and rear hitches.
[0040] From the foregoing, it is to be appreciated that the receiver hitch of the present invention is readily adaptable for receiving a wide variety of inserts, including a winch carrier in a winch mounting system. Other inserts may also be mounted into the receiver hitch for a stable and strong vehicle mounting system.
[0041] Although a particular embodiment of the invention has been described in detail for purposes of illustration, various modifications may be made without departing from the spirit and scope of the invention. Accordingly, the invention is not to be limited, except as by the appended claims.
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An improved receiver hitch having a plurality of receivers is provided. The improved receiver hitch may be used with inserts that are slidably mounted into one or more of the plurality of receivers. The improved receiver hitch may be used with an insert such as a winch carrier in a winch mounting assembly or with other inserts such as ball mounts, clevis mounts, etc. The improved receiver hitch enables better handling, increased capacity, etc.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to machine tools, and, more particularly, to hydraulic apparatus for laterally displacing a rotating cutting element.
2. Description of the Prior Art
Various machine tools can be found in the prior art for laterally positioning a rotating cutting element. One of the earliest devices included a gear operated sliding assembly. The rate of lateral movement of the sliding assembly was a function of the gear ratio. The gear ratio was generally not variable without dismantling the machine tool. The resultant lost time during gear changes wasted valuable machinists' time and increased the cost of the product being fabricated. In addition, machinists would at times use improper gear ratios in an effort to expedite the machining process. Such action tended to produce less than optimum quality work.
To overcome the lack of variability in gear drive mechanisms, electro-mechanical devices were developed. These devices are generally satisfactory in performance but generate other problems. They need external electrical power sources and appropriate electrical switching gear to transmit electrical power from the source to the rotating machine tool. Furthermore, the continual presence of metallic shavings and cutting oil presented a hazard as they might short circuit the electrical components.
Several hydraulically operated laterally displaceable machine tools have also been developed. U.S. Pat. No. 3,422,705 illustrates a machine tool for cutting internal annular recesses using an ancillary hydraulic pressure source to actuate a piston. Movement of the piston is translated through a link to effect lateral movement of a rotating cutting element. U.S. Pat. No. 3,526,159 teaches a hydraulically operated machine tool for laterally displacing a rotating cutting element. An external source provides hydraulic fluid under pressure to axially displace a piston. Lateral movement of the piston is translated through gears to rotate a threaded shaft. Rotation of the shaft causes longitudinal displacement of the shaft which acts upon an inclined plane to laterally displace the cutting element.
Both of the above described hydraulic tools cannot be easily used on any existing jig bores or milling machines as each requires an external source of pressurized hydraulic fluid. In addition, the requirement for shafts and pistons aligned with the axis of rotation of the tool necessarily limits their minimum length. Thus, for any given jib bores or milling machines the size of the work piece is severly limited.
It is therefore a primary object of the present invention to provide a self contained machine tool having a laterally displaceable cutting element.
Another object of the present invention is to provide a compact machine tool having a laterally displaceable cutting element.
Yet another object of the present invention is to provide a machine tool having selectively operated means for effecting infinitely variable lateral movement of a cutting element.
Still another object of the present invention is to provide a machine tool having manually operated means for controlling the surface finish effected by a cutting element.
A further object of the present invention is to provide a machine tool having a selectively variable rate of lateral movement of a cutting element.
A yet further object of the present invention is to provide a rotating machine tool with a vertically displaceable non-rotating annular member to reciprocate a pair of diametrically opposed hydraulic fluid pumps and to generate a hydraulic force for laterally displacing a cutting element.
A still further object of the present invention is to provide a guick return to the start position of a hydraulically positioned laterally displaceable cutting element in a machine tool.
It is also an object of the present invention to provide a hydraulically operated machine tool having a hydraulic fluid pressure takeoff to operate a hydraulic mechanism for varying the angular orientation of the cutting element.
It is also another object of the present invention to provide hydraulically operated attachments useable in conjunction with a hydraulic fluid pressure takeoff in a hydraulically operated machine tool.
These and other objects of the present invention will become apparent to those skilled in the art as the description thereof proceeds.
SUMMARY OF THE INVENTION
The present invention may be described as a rotating machine tool having self contained hydraulic means for positioning a rotating cutting element lateral to the axis of rotation. An arbor, extending upwardly from the main body of the machine tool, is secured within the chuck of a rigid spindle machine, or the like, to effect rotation of the main body. A sliding collar, having an inclined annular recess is attached to the main body concentric with the arbor. A pair of diametrically opposed spring biased plungers mounted within corresponding cylinders are in engagement with the recess. One of two input lines interconnects each cylinder to a common hydraulic fluid reservoir internal to the main body through respective check valves. One of two output lines connect each cylinder to a common pressure chamber. An output line from the chamber channels a flow of hydraulic fluid into the cylinder of a piston and cylinder assembly. The piston acts upon a spring biased slidable mounting assembly for the cutting element. The operation of the present invention may be summarized as follows. The machine tool is rotated by actuating the rigid spindle machine. By restraining the rotary motion of the slidable collar, the non-rotating inclined recess will cause reciprocal movement of the plungers as they ride within the recess resulting in a pumping action within each cylinder to force a flow of hydraulic fluid from the reservoir to the chamber. The pressure buildup within the chamber results in a corresponding movement of the piston to laterally displace the cutting tool mounting assembly. Actuation of a relief valve intermediate the chamber and the reservoir drops the pressure within the chamber and the mounting assembly is free to return under the force of the bias springs. To vary the amount by which the plungers are displaced per revolution of the machine tool, a positionable inclined swash plate may be located intermediate the inclined recess and the plungers.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention may be described with greater specificity and clarity with reference to the following drawings, in which:
FIG. 1 illustrates the present invention attached to a rigid spindle machine or the like.
FIG. 2 illustrates a top view of the present invention taken along lines 2--2, as shown in FIG. 1.
FIG. 3 illustrates a cross-sectional view of the present invention taken along lines 3--3, as shown in FIG. 2.
FIG. 4 illustrates a further cross-sectional view of the present invention taken along lines 4--4, as shown in FIG. 2.
FIG. 5 illustrates a bottom view of the present invention taken along line 5--5, as shown in FIG. 1.
FIG. 6 illustrates a cross-sectional view of the pressure chamber of the present invention.
FIG. 7 illustrates an exploded view of the hydraulic system of the present invention.
FIG. 8 illustrates a hand tool for retaining the collar of the present invention.
FIG. 9 depicts a hydraulically operated cutting tool useable with the present invention.
FIG. 10 illustrates an end view of the cutting tool shown in FIG. 9, taken along lines 10--10.
FIG. 11 depicts a further hydraulically operated cutting tool useable with the present invention.
FIG. 12 illustrates a cross-sectional view of the further cutting tool shown in FIG. 11, taken along lines 12--12.
FIG. 13 illustrates a cross-sectional view of the cutting tool shown in FIG. 12, taken along lines 13--13.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, there is shown a rigid spindle machine 1, or the like, having a rotatable receiver, or collet 2. The main body 4 of the present invention includes an upwardly extending arbor 3, which arbor is firmly secured within collet 2. A collar 5, rotatably mounted upon body 4, is essentially concentric with arbor 3. The lower part of body 4 includes a pair of downwardly extending supports 9 and 10. A pair of rods 7 are secured within supports 9 and 10 and extend across the recess intermediate the supports. A carriage 6 is slidably mounted upon the rods and biased in one direction by coil springs 8. A barrel 16, which may be formed as a part of carriage 6, extends downwardly from the carriage. Barrel 16 is essentially aligned with the center line of arbor 3 when carriage 6 has been positioned to the extreme right (as shown) under force of coil springs 8. An adjustment screw 15 may be incorporated to limit the movement of carriage 6 to the right. A cutting element or tool, generally identified by numeral 17, is rigidly secured within barrel 16. The movement of carriage 6 to the left may be limited by an adjustment screw, not shown, mounted within support 9. An axially retained disc 18 having a threaded aperture is turned to position the screw to the left or right. A housing 11 extending from support 9 encloses and protects the screw.
As will be described in further detail below, the positioning of carriage 6 is accomplished through a self contained hydraulic system disposed within body 4. An access cap 14 may be provided to permit access to a part of the hydraulic system. A fitting 12, normally capped by cap 13 (see FIG. 2), communicates with a hydraulic fluid pressure chamber interior to body 4 and includes a check valve to prevent loss of hydraulic fluid pressure therethrough. The fitting 12 can serve as a source of pressurized hydraulic fluid for an angularly displaceable hydraulically operated cutting tool 17.
The collar 5 is shown in further detail in FIG. 2. The periphery of collar 5 is formed by a vertically extending ridge 20 having a groove 19 (see FIG. 1) disposed therein. An aperture 23 is formed within planar base 21. Aperture 23 is internally shouldered to receive the radial flange 24 extending about arbor 3. A plurality of bolts 25 extend through flange 24 and secure the flange to body 4. A pair of arcuate apertures 22 and 26 are also disposed within base 21 concentric with aperture 23. A swash plate 28, visible through apertures 22 and 26, is selectively positionally retained adjacent the bottom of collar 5 by means of a pair of snubbing nuts 29 and 30 extending through apertures 22 and 26, respectively. By loosening the snubbing nuts, swash plate 28 may be rotated with respect to collar 5 to the extent of the arc defined by apertures 22 and 26.
The mechanisms disposed within body 4 will be primarily described with reference to FIG. 3. The pepriphery of radial flange 24 is shouldered to mate with the shoulder of aperture 23. The relative dimensions are such that the lower surface 32 of collar 5 is adjacent to but not in frictional engagement with the upper surface 33 of body 4. A hollow stud 34 extends downwardly from flange 24 and fits within a downwardly extending circular cavity 35 formed within body 4. A seal intermediate stud 34 and cavity 35 is obtained by an O-ring 36 located within an annular recess 37 in the stud. A cylindrical cavity 38 extends upwardly from within stud 34 into arbor 3. A piston 39 is positioned within cavity 38. An O-ring 40 is located within an annular recess 41 in the piston 39 to provide a seal between the cavity and the piston. Thereby, the piston prevents communication between the cylindrical cavity 38 and the axial cavity 42 at the top of arbor 3.
A downwardly opening annular recess 44 is disposed within collar 5 concentric with aperture 23. The base 45 of recess 44 is inclined whereby the base defines a plane not normal to the axis of collar 5. The swash plate 28 is a ring slidably disposed within recess 44. The plane defined by the lower surface 47 of swash plate 28 is inclined with respect to the plane defined by the upper surface of the swash plate at the same angle as the base 45 of recess 44 is inclined with respect to a plane perpendicular to the axis of collar 5. The swash plate 28 may be milled to remove a portion of the lower surface to leave a shoulder 46 about the periphery of the swash plate.
From the above description, it may be understood that swash plate 28 is in the nature of a wedge when it is disposed within recess 44. In one position of the swash plate 28, the lower surface 47 is angled with respect to the axis of collar 5 by an amount equal to the sum of the angular displacement of base 45 and wedge angle formed by the swash plate. If the swash plate 28 is then rotated 180°, the angle formed by base 45 is complementary to the wedge angle formed by swash plate 28 whereby, the lower surface 47 of the swash plate is essentially normal to the axis of collar 5. The amount of rotational adjustment of swash plate 28 with respect to collar 5 is limited by the angle described by arcuate apertures 22 and 26 (see FIG. 2). It is also to be understood that the angles defined by the planes of the base 44 and the swash plate 28 may be identical to or different from one another.
Diametrically opposed cylindrical cavities 50 and 51 are disposed equidistant from the axis of rotation of body 4. Sleeves 52 and 53 are inserted within cavities 50 and 51, respectively. Plungers 54 and 55 are mounted within sleeves 52 and 53, respectively. These plungers include one or more O-ring 58 located within annular recesses 59 in the respective plungers to permit axial movement of each plunger within its respective sleeve and yet maintain a seal intermediate each plunger and its sleeve. Arcuate spherical radius ends 56, 57 extend upwardly from plungers 54 and 55, respectively. A non-rotating ring 60 lies adjacent lower surface 47 of swash plate 28. Spherical radius ends 56 and 57 engage recesses 61 and 62, respectively, formed within the ring.
As discussed above, the lower surface 47 of swash plate 28 may be either normal to the axis of collar 5 or may be at an angle therewith depending upon the angular positioning of the swash plate with respect to the collar. If the lower surface 47 is normal to the axis of collar 5, rotation of the swash plate, the latter sliding upon ring 60, will cause no axial displacement of the ring. However, if the angle defined by lower surface 47 is not normal to the axis of collar 5, one point of the lower surface of the swash plate will be higher above the upper surface 33 of body 4 than the diametrically opposed point on the swash plate.
Plungers 54 and 55 are upwardly biased by means of coil springs 63 and 64, respectively. Thus, plungers 54 and 55 will tend to exert an upward force upon ring 60 to maintain the latter in constant contact with lower surface 47 of swash plate 28. The ensuing rise and drop of ring 60 at a given point, such as plungers 54 and 55, when there is relative rotational movement between the swash plate and the ring, will cause the plungers to move upwardly and downwardly. The amount of upward and downward travel of plungers 54 and 55 is determined by the orientation of the swash plate as set by the snubbing nuts 29 and 30 (see FIG. 2). Thereby, the volumetric displacement of each of the plungers per revolution of collar 5 with respect to body 4 can be adjusted and set.
In the following description of the hydraulic system of the present invention, reference will be made jointly to FIGS. 3 and 7. A collar 66, which may be of nylon, is placed at the bottom of circular cavity 35. A ball check valve 68 is disposed within a radial passageway 67 extending through collar 66. A hydraulic line 69, which may be formed as an integral part of body 4, interconnects passageway 67 with a sump 70 at the base of cavity 50. Another hydraulic line 71 interconnects sump 70 with a pressure chamber 72. Both line 71 and chamber 72 may also be formed as integral parts of body 4. A second ball check valve 74 is disposed within another radial passageway 73 in collar 66. A line 75 interconnects passageway 73 with a sump 76 at the bottom of cavity 51. A further hydraulic line 77 interconnects sump 76 with chamber 72. Hydraulic lines 75 and 77 may also be formed integral with body 4.
From this description, it may be understood that the reciprocal action of plungers 54 and 55, biased by springs 63 and 64, respectfully, will generate cyclical pressure variations within the respective sumps to draw fluid through hydraulic lines 69 and 75 and pump the fluid into chamber 72. The ball check valves, of course, prevent return of the fluid through the passageways into the collar.
The central part of collar 66, in combination with cylindrical cavity 38, serves as a hydraulic fluid reservoir from which the fluid is pumped and to which it is returned.
Referring momentarily to FIGS. 4 and 7, the pressure relief within chamber 72 and the return of hydraulic fluid to the reservoir will be described. A hydraulic line 83, which may be formed integral with body 4, interconnects chamber 72 with a recess 82 formed in the external surface of collar 66 and defining a passageway in combination with the surface of cavity 35. A ball check valve 81 is disposed within a radial passageway 80, which passageway connects with recess 82. A plunger 84 is locaated within a cylindrical cavity 93 formed in body 4. A seal intermediate the plunger and the cavity may be established by one or more O-rings 88 mounted within annular recesses 89 in the plunger. The plunger 84 is aligned with passageway 80 and includes a tip 85 extending into the passageway to act upon the ball of ball check valve 81. A manually operated lever 90 is pivotally secured to body 4 by pin 91. Lever 90 contacts plunger 84, and when pushed toward body 4, axially displaces plunger 84 to unseat the ball in the ball check valve. A coil spring 92 may be incorporated to bias lever 90 away from body 4. It may therefore be understood that by the pressing lever 90, plunger 84 unseats the ball in ball check valve 81 and fluid, under pressure within chamber 72, will flow through hydraulic line 83, recess 82 and passageway 80 into the reservior. The ball of the ball check valve may be biased by a coil spring 86 extending toward the ball from a diametrically opposed recess 87. Means may be incorporated to vary the bias provided by spring 86.
The apparatus and mechanism for moving carriage 6 will be described with reference to FIGS. 3, 5 and 7. Carriage 6 is journalled upon a pair of rods 7, which rods extend from and are secured within supports 9 and 10. A coil spring 8 about each of rods 7 biases carriage 6 toward support 10. The extent of movement of carriage 6 toward support 10 is essentially determined by adjustment screw 15 threadedly engaging support 10. The movement of carriage 6 toward support 9 is limited by a further adjustment screw 94. Adjustment screw 94 is housed within a sleeve 95, which sleeve is mounted within an aperture extending through support 9. The extension and retraction of screw 94 is controlled by disc 18 having a central threaded aperture engaging the threads of screw 94. The disc 18 is free to rotate within a slot in support 9 but is axially constrained to prevent any movement of the disc along the axis of screw 94. By rotating disc 18, screw 94 is axially displaced. The face of disc 18, if the threads of screw 94 are calibrated, may include indicia to indicate the extent of axial displacement of the screw. The stud of screw 94, is protected by a housing 11 threadedly engaging sleeve 95.
Referring particularly to FIG. 7, the movement of piston 100 in response to reciprocal action of plungers 54 and 55 will be described. As plungers 54 and 55 reciprocate in response to relative movement between collar 5 and body 4, hydraulic fluid is pumped into chamber 72. The fluid within chamber 72 is transported therefrom and into a sleeve 99 through a hydraulic line 98. The hydraulic line 98 may be formed as an integral part of body 4 to mate with an aperture in sleeve 99. The hydraulic fluid flows into sleeve 99 intermediate the sleeve base 106 and the rear surface 107 of a piston 100. The flow of hydraulic fluid into sleeve 99 will cause piston 100 to travel away from sleeve base 106. As the piston travels, the face 104 of the piston will exert a force against the bottom 105 of a cavity 103 disposed within carriage 6 and cause the carriage to move toward support 9. The movement of carriage 6 will be countered by the force exerted upon coil springs 8. Thereby, the movement of carriage 6 will be controlled and well defined.
Carriage 6 is returned adjacent the end of adjustment screw 15 by depressing lever 90 to release the pressure within chamber 72. The resulting loss of pressure within sleeve 99 acting upon piston 100, permits the carriage to return under force of coil springs 8.
Barrel 16 may include a cavity 110 to receive the shank of cutting tool 17. A set screw 111 engaging a threaded aperture retains the cutting tool shank within cavity 110.
Referring to FIGS. 4, 5 and 6, the hydraulic fluid pressure takeoff fitting 12 will be described in further detail. In the preferred embodiment of the present invention, chamber 72 is formed as a cylindrical cavity within body 4. The cavity opening may be sealed, or fitting 12 may be threadedly secured to the cavity. Fitting 12 includes a ball check valve 113 to permit hydraulic fluid flow therethrough when the ball is unseated. An O-ring 114 is disposed intermediate body 4 and a recess within shoulder 115 to maintain and preserve the pressure within chamber 72. A further fitting, mating with fitting 12, may be used to convey hydraulic fluid under pressure to a further operating element used in conjunction with the present invention. In example, the cutting tool 17 may include a hydraulically actuated mechanism for effecting angular displacement of the cutting tool. In such case, a hydraulic line would be connected intermediate fitting 12 and the hydraulic mechanism of cutting tool 17. With such an arrangement, it is possible to obtain not only lateral displacement of cutting tool 17 but also concurrent angular displacement. Thus, a single cutting or milling operation may be carried out which previously required two operations.
Referring to FIG. 8, there is shown a manually operated tool for gripping collar 5. When rigid spindle machine 1 is energized to rotate collet 2, arbor 3 will rotate and, as it is fixedly secured to body 4, the body will rotate. Unless rotation of collar 5 is restrained, the collar will rotate with the body. In this case, no pumping action will be effected by plungers 54 and 55 as there will be no upward and downward movement of ring 60. If rotation of collar 5 is restrained, the swash plate, if adjusted so that its lower surface 47 is non-perpendicular with the axis of rotation, will cause axial displacement of ring 60 and generate a pumping action by the plungers. The rotation of collar 5 can be restrained by manually gripping the collar. In the alternative and for safety reasons, it is desirable to employ a tool to grasp collar 5. The tool may be formed as a fork 120 having curved arms 121 and 122. At the extremity of each of these arms there is disposed a shoe 123 and 124, respectively. A trigger 130 is pivotally mounted within a slot 127 of handle 129 at pivot point 126. An arm 131 of trigger 130 pivotally engages a shaft 128. By pivoting trigger 130 about pivot point 126, the arcuate movement of arm 126 will cause axial displacement of shaft 128. Shaft 128 extends interior to arms 121 and 122. A further shoe 125 is secured to the extremity of shaft 128. Each of shoes 123, 124 and 125, are formed to engage groove 19 extending about the external surface of ridge 20 in collar 5. The curvature and extent of arms 121 and 122 are configured such that shoes 123 and 124 are beyond the center line of collar 5. By depressing trigger 130, shoe 125 will be forced toward shoes 123 and 124, which action will tend to squeeze groove 19 therebetween. The frictional engagement between shoes 123, 124, 125 and groove 19 will tend to restrain rotation of collar 5 despite continuing rotation of body 4. Thus, the tool shown in FIG. 8 may be employed to restrain rotation of collar 5.
Previously, the cutting element attachable to the present invention was generally identified by numeral 17 (see FIG. 1). As discussed earlier, the cutting element may be a simple blade having no movement independent of the movement generated by the main body 4. To increase the versatility of the present invention, an independently movable cutting tool 17 may be used. It is operated by the hydraulic pressure generated within chamber 72. The features and operation of this cutting tool will be described with joint reference to FIGS. 1, 3, 9 and 10.
Cavity 110 within barrel 16 is configured to receive holder 150 of cutting tool 17. A depression 151 within holder 150 is configured to receive the end of set screw 111. Thereby, cutting tool 17 is attached to carriage 6 of the present invention.
A casing 152 extends lateral to holder 150 and houses a hydraulically operated piston 155. Hydraulic fluid is conveyed into and out of casing 152 through a conduit 153. The conduit 153 is operably connected to the source of hydraulic pressure within chamber 72 by means of fitting 154 mating with fitting 12 after removal of dust cap 13 (see FIG. 2).
In the embodiment shown, conduit 153 is permanently secured to and extends through a cover plate 160 attached to the end of casing 152. An O-ring 161 may be disposed intermediate cover plate 160 and casing 152 to insure a sealed end for cylinder 156. Piston 155 is disposed within cylinder 156 and may include one or more O-rings 157 to form a seal against the wall of the cylinder. The piston is biased toward cover plate 160 by means of coil spring 158 disposed within cylinder 156. An annular step 159 may be formed within the lower end of the skirt of piston 155 to position the coil spring axially within the cylinder. A rack 162 extends from piston 155 and is axially positionable in conformance with movement of the piston.
As rack 162 is axially repositioned, the teeth 164 disposed therein engage an idler gear 163 mounted upon shaft 167 and cause the idler gear to rotate. A tool actuating gear 165 mounted upon a shaft 168 is in mesh with idler gear 163. The tool actuating fear 165 is non-rotatably secured to a housing 169 such that any rotary movement of the tool actuating gear will cause an equal and corresponding movement of the housing. A cutting element 170 is mounted within housing 169 and secured thereto by means of a set screw 171.
One end of a restraining spring 166 is in engagement with the main body of cutting tool 17. The other end of restraining spring 166 acts upon a stop 172 extending from housing 169. Restraining spring 166 is biased to counter rotational movement of housing 169 caused by tool actuating gear 165.
A dust cap 173 may be attached to the main body of cutting tool 17 by a bolt 175. The dust cap 173 protects the end of rack 162 when the latter is extended from within the main body of the cutting tool through aperture 176. A limit screw 174 may threadedly engage dust cap 173 to limit the movement of rack 162.
The operation of hydraulically actuated cutting tool 17 may be described as follows. When a pressure buildup occurs within pressure chamber 72, hydraulic fluid will be forced through fitting 154 and conduit 153 into the space intermediate the top of piston 155 and cover plate 160. The increasing volume of hydraulic fluid adjacent the piston within casing 152 will cause the piston to be displaced within cylinder 156. Displacement of piston 155 will cause a commensurate displacement of rack 162 resulting in rotational movement of idler gear 163. Idler gear 163, being in mesh with tool actuating gear 165, will cause housing 169 and attached cutting element 170 to be angularly repositioned with respect to the axis of holder 150. As the angular displacement of housing 169 is a direct function of the amount of travel of rack 162, the maximum angular displacement of the housing may be limited by limit screw 174, which limit screw limits the maximum movement of the rack.
A further independently positionable cutting tool 185 attachable to main body 4 of the present invention will be described with reference to FIG. 11, 12 and 13. Cutting tool 185 includes a mount assembly 186 attachable directly to carriage 6 by plate 184 and bolts 187. The body 188 of cutting tool 185 is pivotally connected to mount assembly 186 by means of a bolt 189.
Body 188 is formed of two primary members, a base frame 190 and a movable carriage 191. The base frame 190 is pivotally connected to the mount assembly 186. It may include indicia on the outer surface thereof representative of its angular position with respect to the axis of the arbor 8 (see FIG. 1). The movable carriage 191 is in slidable engagement with the base frame by means of a dove tail interface generally identified by numeral 192. An adjustable strip or gib 193 is employed to obtain a proper fit at the dove tail interface 192. A plurality of adjustment screws 194 extend into a base frame 190 to act against gib 193 to properly position the latter. Thereby, the play between the base frame and the movable carriage is maintained at a minimum.
The movable carriage 191 includes a cavity 195 for receiving the cutting implement 197 (see FIG. 11). A set screw 196 retains the cutting implement 197 in place.
An axially oriented cylinder 200 is disposed within base frame 190. A piston 201 is slidably positioned within cylinder 200 and may include one or more peripherally mounted O-rings 202 to effect a seal intermediate the piston and the cylinder. A piston rod 204 extends downwardly from piston 201 and is secured within a cavity in the lower part of movable carriage 191 by means of a set screw 205. A coil spring 203 is disposed within the cylinder to bias piston 201 in the illustrated upward direction. The lower skirt of piston 201 may include an annular step 207 to receive one end of coil spring 203. The illustrated lower end of cavity 200 may include an apertured cap 206 to restrain downward movement of coil spring 203 and guide the piston rod 204 extending therethrough.
Hydraulic fluid is introduced within cylinder 200 adjacent the top of piston 201 by means of a conduit 210 attached to base frame 190. Conduit 210 terminates in a fitting 211, which fitting mates with and is attachable to fitting 12 extending from main body 4 (see FIG. 1).
The periphery of the base frame 190 and the movable carriage 191 at the junction therebetween (see FIG. 11) includes indicia indicative axial movement of the movable carriage with respect to the base frame. The movement of the movable carriage can be limited by means of a thumb screw 212 engaging a worm gear 213.
In operation, the angular orientation of cutting tool 185 with respect to the arbor 3 is set by loosening bolt 189, pivoting the cutting tool and retightening the bolt. When a hydraulic fluid pressure buildup occurs within chamber 72, hydraulic fluid will flow through fitting 12, fitting 211, conduit 210 and into the cylinder 200 adjacent the top surface of piston 210. The flow of hydraulic fluid will force a downward movement of piston 210, which downward movement is translated by piston rod 204 into a movement of a movable carriage 191. Thereby, the cutting implement 197 will be axially displaced in proportion to the pressure buildup within chamber 72.
As will be obvious to those skilled in the art, the cutting tool illustrated in FIG. 9 provides a means by which the cutting implement may be angularly positioned while the pivot point of the cutting implement is laterally and vertically repositioned. Similarly, the cutting tool illustrated in FIG. 11 permits the cutting implement to be displaced along its axis simultaneously with vertical and lateral repositioning of the cutting implement. Thereby, these cutting tools provide a range of cutting configurations never before realized in the machine tool art.
While the principles of the invention have now been made clear in an illustrative embodiment, there will be immediately obvious to those skilled in the art many modifications of structure, arrangement, proportions, the elements, material, and components, used in the practice of the invention which are particularly adapted for specific environments and operating requirements without departing from those principles.
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A rotating machine tool for hydraulically positioning a cutting tool mounting assembly lateral to the axis of rotation is disclosed. A collar circumscribing the axis of rotation and having an inclined annular downwardly directed recess is slidably mounted on the machine tool. A pair of diametrically opposed plungers ride within the inclined recess and are forced into reciprocal movement thereby. The reciprocating plungers pump hydraulic fluid from a reservoir within the machine tool into a pressure chamber. The pressure chamber is connected to a piston and cylinder assembly, which piston is positionally responsive to the pressure within the chamber. The movement of the piston is translated into lateral movement of the cutting tool via a spring biased mounting assembly. In operation, the rotation of the collar is restrained while the body of the machine tool rotates. The difference in rotation rate between the collar and the body causes the plungers within the body to ride upon the inclined annular recess and induces pumping of the hydraulic fluid. The hydraulic fluid is pumped into the pressure chamber and an increase in pressure therein causes the mounting assembly to be displaced. Actuation of a relief valve connected to the pressure chamber permits the mounting assembly to return to its initial position in response to the force exerted by the bias springs. The inclined annular recess may be mated with a mirror image positionable swash plate to provide selectively variable maximum vertical movement to the plungers to vary the rate of pumping. Hydraulically operated cutting tool attachments connectable to a hydraulic fluid takeoff on the assembly are also described.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority as a continuation-in-part to U.S. patent application Ser. No. 12/804,602, filed on Apr. 19, 2010, entitled BOLTED STEEL CONNECTIONS WITH 3-D JACKET PLATES AND TENSION RODS, by WeiHong Yang, the contents of which are hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates generally, to construction material, and more specifically, to a steel jacket plate connector.
BACKGROUND
[0003] During construction of steel frames and trusses, individual members such as beams and columns are connected together to form a structure. Conventionally, two-dimensional gusset plates are used to connect steel members with either welding or bolts, or their combinations.
[0004] However, connecting steel beams requires a degree of physical fitness and expertise that can make it a difficult job. Typically, each connection is custom fit on site while steel members are held in place. The labor cost of welders assembling connectors on site can be prohibitive. Moreover, the time to construct a structure is lengthened by the connections because adjacent members cannot be added until a supporting member is secured.
[0005] What is needed is a technique to allow faster and lower cost installation of connections.
SUMMARY OF THE INVENTION
[0006] The above needs are met by an apparatus, system, method and method of manufacture for a three-dimensional jacket-plate connector.
[0007] In one embodiment, the 3-D connector comprises first three-dimensional jacket plate. A second three-dimension jacket plate that is a mirror image of the first three-dimensional jacket plate. The two jacket plates are bolted to opposite sides of a joint of the steel I-beam members.
[0008] In another embodiment, a jacket plate comprises a primary c-channel welded to a connecting c-channel that intersect to match angles of the joint formed by a primary I-beam member and a connecting I-beam member.
[0009] Advantageously, the 3-D jacket connection can achieve exceptional structural performance, including higher strength and ductility, stronger yet simpler connections, higher quality, small components for easy storage and transportation. It also provides easy installation to increase the speed and reduce the price of erecting steel structures. The 3-D jacket connection addresses all possible connection type in such a simple and yet consistent manner that it is practically a versatile connections system that can be use in any steel frames and trusses that is made of wide-flanged steel I-beam sections.
BRIEF DESCRIPTION OF THE FIGURES
[0010] In the following drawings like reference numbers are used to refer to like elements. Although the following figures depict various examples of the invention, the invention is not limited to the examples depicted in the figures.
[0011] FIGS. 1A-E are schematic diagrams illustrating steel frames, according to some embodiments.
[0012] FIGS. 2A-D are schematic diagrams illustrating steel trusses, according to some embodiments.
[0013] FIGS. 3A-B are schematic diagrams illustrating a moment connection at a top floor, corner condition, of the steel frame of FIG. 1A , according to some embodiments.
[0014] FIGS. 4A-B are schematic diagrams illustrating a moment connection at an intermediate floor, side condition, of the steel frame of FIG. 1A , according to some embodiments.
[0015] FIGS. 5A-B are schematic diagrams of a moment connection at a top floor, interior bay condition, of the steel frame of FIG. 1A , according to some embodiments.
[0016] FIGS. 6A-B are schematic diagrams illustrating a moment connection at an intermediate floor, interior bay condition, of the steel frame of FIG. 1A , according to some embodiments.
[0017] FIGS. 7A-D are schematic diagrams illustrating a moment connection of an eccentrically braced frame (EBF), of the steel frame of FIG. 1B , according to some embodiments.
[0018] FIGS. 8A-D are schematic diagrams illustrating a moment connection of special concentrically braced frame (SCBF), of the steel frame of FIG. 1C , and the similar connections of the steel truss of FIG. 2D , according to some embodiments.
[0019] FIGS. 9A-D are schematic diagrams illustrating a moment connection of an EBF and an inverted V SCBF, brace and beam to column connection, of the steel frame of FIG. 1D , and the similar connections of the steel truss of FIG. 2C , according to some embodiments.
[0020] FIGS. 10A-D are schematic diagrams illustrating a moment connection of an EBF and an inverted V SCBF, brace and column connection at a foundation, of the steel frame of FIG. 1B , according to one embodiment.
[0021] FIGS. 11A-D are schematic diagrams illustrating a moment connection of an SCBF, braces and beam to column connection at a floor, of the steel frame of FIG. 1D , according to one embodiment.
[0022] FIGS. 12A-F are schematic diagrams illustrating a moment connection of an SCBF, brace and beam to column connection at a top floor, of the steel frame of FIG. 1E , according to some embodiments.
[0023] FIGS. 13A-B are schematic diagrams illustrating a moment connection of an SCBF, brace and beam crossing connection, of the steel frame of FIG. 1D , according to some embodiments.
[0024] FIGS. 14A-C are schematic diagrams illustrating a moment connection of an SCBF, brace crossing connection without beam condition, of the steel frame of FIG. 1E , according to some embodiments.
[0025] FIGS. 15A-C are schematic diagrams illustrating a Vierendeel truss, connection condition, of the steel truss of FIG. 2A , according to one embodiment.
[0026] FIGS. 16A-B , are schematic diagrams illustrating a steel bridge truss segment, of the steel truss of FIG. 2B , according to one embodiment.
DETAILED DESCRIPTION
[0027] An apparatus, system, method, and method of manufacture for a three-dimensional jacket-plate connector to connect at least two members that are wide-flanged steel I-beam sections, are described herein. The following detailed description is intended to provide example implementations to one of ordinary skill in the art, and is not intended to limit the invention to the explicit disclosure, as one of ordinary skill in the art will understand that variations can be substituted that are within the scope of the invention as described.
System Overviews (FIGS. 1 and 2)
[0028] FIGS. 1A-E are schematic diagrams illustrating steel frames, according to some embodiments. The steel frames are composed of steel I-beam sections that connect at a joint. The label numbers associated with the joints in FIGS. 1A-E correspond to figure numbers that further detail the joint. More particularly, FIG. 1A shows a steel frame with moment connections 3 , 4 , 5 and 6 further detailed in FIGS. 3A-B , 4 A-B, 5 A-B and 6 A-B; FIG. 1B shows an eccentrically braced frame (EBF) with moment connections 7 , 9 and 10 , further detailed in FIGS. 7A-D , 9 A-D and 10 A-D, respectively; and FIG. 1C shows a specially concentrically braced frame (SCBF) with a moment connection 8 further detailed in FIG. 8A-D .
[0029] FIGS. 2A-D are schematic diagrams illustrating steel trusses, according to some embodiments. The label numbers associated with the joints in FIGS. 2A-D correspond to figure numbers that further detail the joint. Specifically, FIG. 2A illustrates a Vierendeel truss connection condition 15 further detailed in FIGS. 15A-C , FIG. 2B shows a steel bridge truss segment further detailed in FIGS. 16A-B , FIG. 2C shows an EBF and an inverted V SCBF with a moment connection 9 further detailed in FIGS. 9A-D , and FIG. 2D shows a steel truss with a connection 8 further detailed in FIGS. 8A-D .
Individual 3-D Connector and Accessory Details
[0030] FIGS. 3A-B are schematic diagrams illustrating a moment connection 300 at a top floor, corner condition, of the steel frame of FIG. 1A , according to some embodiments. FIG. 3A shows the moment connection 300 as assembled in the field, while FIG. 3B is an exploded view. The moment connection 300 is an (L)-shaped connection. The top floor corner 300 includes a 3-D connection between, for example, a post 310 and a beam 320 (also generically referred to as members herein). The 3-D connection includes 3-D jacket plates 301 , 302 , which are mirror images to each other.
[0031] The post 310 and beam 320 are configured as I-beams or I-beam sections (i.e., two opposing flanges connected by a web). The members 310 , 320 are composed of construction-grade steel, or any appropriate material. The sizes are variable. In some embodiments, the post 310 and beam 320 are different sizes because the post 310 typically supports a load of greater magnitude.
[0032] The 3-D jacket plates 301 , 302 are composed of, for example, steel. The plates 301 , 302 can be substantially identical and mirrored for attachment to opposite sides of the joint. The plates can be pre-fabricated off site to match sizes and strength requirements of the structure. Common sizes can be mass produced in a manufacturing facility. The 3-D jacket plates 301 , 302 can be formed from c-channels having a web (or side) plate welded to two flange (or clamping) plates. Alternatively, the 3-D jacket plates 301 , 302 can be formed from a side plate in the shape of a joint (i.e., (L)-shaped) and clamping plates welded around a perimeter of the side plate at, for example, a perpendicular angle.
[0033] In some embodiments, formation or manufacture of the 3-D jacket plates 301 , 302 begins with a primary c-channel which can correspond to a primary member continued through joint. A connecting c-channel corresponding to a connecting member (i.e., the beam 320 ) can be welded to the primary c-channel. The primary member can be a load carrying member of a connection (i.e., the post 310 ), and the connecting member (i.e., the beam 320 ) can transfer its load to the primary member. The c-channels radiate away from the joint in the direction matching the members 310 , 320 . A sidewall portion of the primary c-channel (i.e., portion of flange or clamping plate) can be notched out to weld a primary c-channel web to a connecting c-channel web. The notch accommodates flanges of the connecting member when installed. The connecting member transfers forces to the primary member through the pair of 3-D jacket plates 301 , 302 .
[0034] Bolts can be used to connect the 3-D jacket plates 301 , 302 to members. In one embedment, a pre-drilled pattern is provided to allow faster installations. Configuration of c-channels of the 3-D jacket plates 301 , 302 relative to connecting I-beam member 320 allows an installer to fit a hand with a fastening tool into a box gap afforded by opposing flanges of the I-beam and the webs of the c-channel and the I-beam.
[0035] One or more tension rods 303 installed across the depth (i.e., through-the-depth steel rods) of the post 310 , in some embodiments, provide additional strength to the primary c-channel of the 3-D jacket plates 301 , 302 . Although the tension rods 303 are shown as connected to the post 310 , this is merely for the purpose of illustration. As installed, the tension rods 303 are connected to the outer portions of the 3-D jacket plates 301 , 302 to reinforce against moment forces. More specifically, the vertical shear force is transferred from the beam 320 to the post 310 through a shear tag similar to those of 505 and 605 , the rotational moment force is completely transferred, from the beam 320 to the post 310 , through the 3-D jacket plates 301 , 302 . The tension rods 303 help to transfer horizontal shear force associated with the moment force, through an inner flange, to the web of the post 310 . In other word, the tension rods 303 reinforce the connector plates 301 , 302 from being pulled away from the outer flange.
[0036] Stiffener (or web stiffener) plates 304 in the post 310 , of other embodiments, provide additional strength to the continued primary I-beam 310 . One more stiffener plates 304 are dispersed as needed. The stiffener plates 304 , coupled with the tension rods 304 , help in transferring bending moment and shear force across the connection.
[0037] FIGS. 4A-B are schematic diagrams illustrating a moment connection 400 at an intermediate floor, side condition, of the steel frame of FIG. 1A , according to some embodiments.
[0038] In this embodiment, the jacket plates 401 , 402 have a (T)-shape (rotated), and are substantially mirror in configuration. As an intermediate floor connection, a beam 420 that is supported by a post 410 which continues vertically to provide support for members at higher elevations, such as a top floor or a roof.
[0039] The jacket plates 401 , 402 have a primary c-channel corresponding to the post 410 and a connecting c-channel corresponding to the beam 420 . One way to form the jacket plates 401 , 402 is to notch out a flange (or clamping) plate of the primary c-channel to allow accommodation for the flanges of beam 420 .
[0040] Tension rods 403 and stiffener plates 404 are placed to counteract the moment force generated by member 420 . Both upper and lower reinforcement are used against both the clockwise and counter clockwise potential rotation of member 420 . A shear tag (similar to those of 505 and 605 , but not shown) can also be included.
[0041] FIGS. 5A-B are schematic diagrams of a moment connection 500 at a top floor, interior bay condition, of the steel frame of FIG. 1A , according to some embodiments.
[0042] In this embodiment, the jacket plates 501 , 502 have a (T)-shape, and are substantially mirror in configuration. Relative to the moment connection 400 of FIG. 4 , the moment connection 500 supports beams on either side of a post rather than at different vertical elevations. Further, tension rods 503 and stiffener plates 504 are dispersed only below the joint. A shear tag 505 is provided to transfer vertical shear forces from I-beam 530 to the post 510 . The rotational moment force is completely transferred, from the beams 520 and 530 to the post 510 , through the 3-D jacket plates 501 , 502 .
[0043] FIGS. 6A-B are schematic diagrams illustrating a moment connection 600 at an intermediate floor, interior bay condition, of the steel frame of FIG. 1A , according to some embodiments.
[0044] In this embodiment, the jacket plates 601 , 602 have a (+)-shape, and are substantially mirror in configuration. In this implementation, the moment connection 600 supports beams 620 , 630 on either side of a post 610 and at different vertical elevations. Here, upper and lower reinforcements are in place. Specifically, tension rods 603 , stiffener plates 604 and a shear tag 605 are shown.
[0045] Additional variations are possible which do not have 90 degree angle joints and have more than two members. The angles can be 45, 30 or 60 degrees, or any angle needed for a structure. In FIGS. 7-16 , numbering labels are consistent with the earlier figures in that connector plates label numbers start with the figure number and end with 01 and 02, tension rods end with 03, web stiffeners end with 04, and shear tags end with 05.
[0046] In particular, FIGS. 7A-D are schematic diagrams illustrating a moment connection 700 of an eccentrically braced frame (EBF), of the steel frame of FIG. 1B , according to some embodiments. In this embodiment, the jacket plates 701 A, 702 A, 701 B and 702 B have a (y)-shape (rotated), and are substantially mirror in configuration.
[0047] FIGS. 8A-D are schematic diagrams illustrating a moment connection 800 of a special concentrically braced frame (SCBF), of the steel frame of FIG. 1C of the steel truss of FIG. 2D , according to some embodiments. In this embodiment, the jacket plates 801 and 802 have the shape of a combination of two rotated and mirrored (y)-shapes, and are substantially mirror in configuration.
[0048] FIGS. 9A-D are schematic diagrams illustrating a moment connection 900 of an EBF and an inverted V SCBF, brace and beam to column connection, of the steel frame of FIG. 1B and the steel truss of FIG. 2C , according to some embodiments. In this embodiment, the jacket plates 901 and 902 have the shape of a combination a rotated (T) and (y), and are substantially mirror in configuration.
[0049] FIGS. 10A-D are schematic diagrams illustrating a moment connection 1000 of an EBF and an inverted V SCBF, brace and column connection at a foundation, of the steel frame of FIG. 1B , according to one embodiment. In this embodiment, the jacket plates 1001 and 1002 have a tilted (V)-shape, and are substantially mirror in configuration.
[0050] FIGS. 11A-D are schematic diagrams illustrating a moment connection 1100 of an SCBF, brace and beam to column connection at a floor, of the steel frame of FIG. 1D , according to one embodiment. In this embodiment, the jacket plates 1101 and 1102 have the shape of a combination of a (K)-shape and a rotated (T)-shape, and are substantially mirror in configuration.
[0051] FIGS. 12A-F are schematic diagrams illustrating a moment connection 1200 of an SCBF, brace and beam to column connection at a top floor, of the steel frame of FIG. 1E , according to some embodiments. In this embodiment, the jacket plates 1201 and 1202 have the shape of a combination of a rotated (L)-shape and rotated (V)-shape, and are substantially mirror in configuration.
[0052] FIGS. 13A-B are schematic diagrams illustrating a moment connection 1300 of an SCBF, brace and beam crossing connection, of the steel frame of FIG. 1D , according to some embodiments. In this embodiment, the jacket plates 1301 and 1302 have a rotated back-to-back dual (K)-shape, and are substantially mirror in configuration.
[0053] FIGS. 14A-C are schematic diagrams illustrating a moment connection 1400 of an SCBF, brace crossing connection without beam condition, of the steel frame of FIG. 1E , according to some embodiments. In this embodiment, the jacket plates 1401 and 1402 have a (X)-shape, and are substantially mirror in configuration.
[0054] FIGS. 15A-C are schematic diagrams illustrating a Vierendeel truss, connection condition, of the steel truss of FIG. 2A , according to one embodiment. In this embodiment, the jacket plates 1501 A and 1502 A have a (T)-shape, and are substantially mirror in configuration; the jacket plates 1501 B and 1502 B have a inverted (T)-shape, and are substantially mirror in configuration.
[0055] Finally, FIGS. 16A-B , are schematic diagrams illustrating a steel bridge truss segment, of the steel truss of FIG. 2B , according to one embodiment. In this embodiment, the jacket plates 1651 has a inverted (T)-shape; the jacket plates 1652 and 1653 has the shape of a combination of a rotated (K)-shape and rotated (T)-shape; and the jacket plates 1654 has a (T)-shape.
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A three-dimensional jacket-plate connector connects at least two members. Each member comprises wide-flanged steel I-beam section. The jacket-plate connector comprises first and second three-dimensional jacket plates.
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FIELD OF THE INVENTION
The present invention relates to stringed and fretted electronic musical instruments which are played in the general manner of a guitar, and more particularly it relates to a fingerboard structure in which the scope of musical control available to a player is greatly expanded, by replacing conventional strings with simulated string-faces made integral with the fingerboard and sensed electronically at fret domains to provide input to an encoder and thence to a processor or synthesizer. The invention provides potential improvement for various fretted instrumental and fingerboard techniques such as regular guitar playing, and is particularly compatible with two-handed tapping techniques.
BACKGROUND OF THE INVENTION
In the conventional manner of playing stringed instruments such as guitars, banjos and the like, strings are pressed against frets on a fretboard or against a fretless fingerboard in order to vary the active string length and thus select the pitch (i.e. frequency) of the note to be played; normally the left hand forms notes and chords while the strings are picked, plucked, strummed or bowed with the right hand which predominantly controls amplitude envelope parameters, particularly the dynamics of each note, such as attack and loudness. This basic approach has been carried over from the purely acoustic category of instruments to the great majority of electronically-amplified stringed instruments in present use, notably the amplified "electric guitar". Even in the more technically sophisticated category of "guitar synthesizers" this traditional string-and-fret system is commonly utilized as the actual interface with the musician; string vibrations are sensed in an pickup whose analog electrical output is converted to a "synthesizer language" such as MIDI, the widely adopted Musical Instrument Digital Interface standards, for further electronic processing into synthesized sounds.
In a departure from the conventional approach of fingering the strings with one hand while strumming or plucking strings with the other hand, a stringed instrument trademarked as The Chapman Stick, introduced in 1974 and disclosed in U.S. Pat. Nos. 3,833,751 and 3,868,880 to Chapman, is played with both hands on the fingerboard; a musical note is initiated by tapping a string against a fret with either hand as opposed to strumming or plucking. This playing technique in conjunction with magnetic string pickups has been practiced using The Stick with analog power amplification and in a synthesizer controller version, trademarked as The Grid, where the pickup signals are MIDI-encoded to facilitate a variety of digital/analog electronic effects. A LAYERED VOICE MUSICAL SELF ACCOMPANIMENT METHOD, for which The Stick and The Grid are particularly well suited, is disclosed in U.S. Pat. No. 4,922,797 to Chapman.
A special requirement of two-handed string tapping technique as taught by Chapman is the need for control over the amplitude envelope, for musical expression, at the same fingertip interface, i.e. the fingerboard, which provides the basic function of pitch selection as each note is played with either hand at the fretboard; this is a fundamental departure from conventional techniques where one hand normally provides pitch selection at the fingerboard while the other hand is mainly dedicated to forming and controlling the amplitude and expression through strumming, picking or plucking motions.
The difficulties and limitations of manufacturing, maintaining and playing conventional string-and-fret instruments are well known, and have prompted numerous efforts to develop alternative approaches which exploit the capabilities of electronic technology. The concept of a stringless fingerboard implemented by electronics overcomes many of these difficulties and limitations which are inherently mechanical in origin. Electronic technology has provided the potential of greatly enhanced control over the various amplitude envelope parameters such as attack, decay, sustain and release, which in mechanical acoustic instruments are subject to severe limitations imposed by the mechanical constraints of the string-and-fret instrument and require a great deal of practice and skill on the part of the player in attempting to develop a degree of control over the envelope through a combination of fingerboard technique with one hand and picking/plucking/bowing technique with the other hand. The ease with which electronics can control envelope parameters in real time facilitates implementation of the concept of a two-handed playing technique wherein a wide range of envelope control capability is provided instantly at each fingertip by advanced human-machine interfacing at a stringless playing surface.
"Stringless" fingerboards which have been proposed in known art have predominantly addressed only the conventional techniques of using only one hand on the fingerboard for selecting pitch. Within this category, U.S. Pat. Nos. 4,339,979 to Norman, 4,177,705 to Evangelista, and 3,340,343 to Woll require some form of strumming or plucking to be performed by one hand, while in U.S. Pat. Nos. 3,555,166 .to Gasser and 4,570,521 to Fox, a piano-type keyboard is to be played by one hand while the other plays the fingerboard or fretboard. Eventoff U.S. Pat. Nos. 4,235,141 and Suzuki et al 3,694,559 disclose fingerboards in which pitch is varied by variable resistance. These approaches and others of known art have been directed to one-handed fingerboard techniques which utilize the fingerboard solely for pitch selection, and thus have failed to address fingerboard control of amplitude envelope parameters, in particular attack velocity, as required for two-handed fingerboard techniques addressed by the present invention.
In playing conventional string-and-fret type instruments, musicians often use a technique known as "pitch bending": a note which has been selected by holding a string against a fret is "bent", i.e. shifted to a higher pitch, by pushing the string laterally along the fret in either direction from its normal position so as to increase the string tension and thus increase the resonant vibration frequency of the string. The pitch cannot be bent to a lower pitch in this manner; however, as a partial remedy to this shortcoming, some instruments are provided with a string tensioning lever, usually operated by the plucking/strumming hand, by which the overall string tension can be varied in either direction, affecting all the strings. This inability to bend the pitch of individual strings downward using the string-and-fret hand is clearly an inherent limitation imposed by the mechanical nature of conventional instruments, and has not been heretofore remedied by known art in either stringed or stringless approaches.
The mechanics of the conventional string-and-fret fingerboard basically restricts finger control to only two dimensions: (1) downwardly, as the string is pressed against a fret in a virtually binary (i.e. on-off) function, and (2) laterally, as the string is stretched sideways to obtain a limited and inflexible degree of upward pitch bending in either of the two opposed lateral directions. However the player's fingers, if suitably interfaced, are capable of movements in other directions which may be utilized advantageously to control various musical effects or parameters such as sustain, reverberation, timbre, etc., directly at the player's fingertips, in a significant extension of the conventional playing techniques of simple note selection and limited pitch bending.
OBJECTS OF THE INVENTION
It is a primary object of the present invention to provide an improved fingerboard and associated encoding electronics to act as a controller for a stringless guitar-like and/or bass-like musical instrument, wherein, in addition to a basic capability of pitch selection in half tone steps similar to conventional string-and-fret technique, a musician is provided with the additional novel capability of controlling amplitude envelope parameters through manipulation of a simulated string-and-fret grid on the fingerboard, as a departure from conventional practice where such amplitude parameters must be controlled apart from the fingerboard in some form of strumming or plucking mechanism which fully occupies one of the musician's hands while the other hand manipulates the fingerboard.
It is a further object to provide such a fingerboard configured in a manner to facilitate playing the instrument with a two-handed tapping technique in which both hands manipulate the fingerboard, each hand independently playing notes in a finger-tapping manner.
It is a further object that the fingerboard controller provide the additional capability of pitch-bending any selected note in response to sideways pressure against a simulated string.
It is a still further object to provide a selectable capability of bending the pitch either upwardly or downwardly at will.
It is a still further object to variably manipulate and control other effects or parameters of the note played by applying pressure against simulated frets in either direction along the string axis.
SUMMARY OF THE INVENTION
The above-mentioned objects have been accomplished in this invention through the concept of a stringless fingerboard controller having a resilient structure with raised longitudinal string-faces simulating conventional strings and having subdominantly raised fret-faces simulating conventional frets. Embedded sensor strips are connected to electronic encoding and processing means such as synthesizers. In performance, a musician, after initially selecting the pitch of a note by visual and/or tactile finger sensing of the simulated string-and-fret structure in the general manner of conventional guitar playing, is enabled to exert control over the amplitude envelope (attack, decay, sustain, release, etc.) of the note via fingertip pressure on the string-face toward the fingerboard surface, and to bend the pitch via lateral pressure against a string-face, in a choice of upward, downward or bidirectional pitch-bending modes.
Furthermore, embodiments of this invention may take advantage of the resilient fingerboard controller and cooperating electronics to achieve further sensing dimensions for fingertip control of additional musical effects and parameters by providing bidirectional response to longitudinal pressure against the fret-faces along the axis of the stringfaces.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and further objects, features and advantages of the present invention will be more fully understood from the following description taken with the accompanying drawings in which:
FIG. 1 is a three-dimensional view of a cutaway end portion of a resilient stringless fingerboard controller of the present invention.
FIG. 2 is a cross section taken through axis 2--2' of FIG. 1.
FIG. 3 is an enlarged view of a portion of FIG. 2.
FIG. 4 is a functional block diagram of a parallel-configured fingerboard controller interfaced to an encoder unit and processor in a first embodiment of the present invention.
FIG. 5 is a functional block diagram of a series-configured fingerboard controller interfaced to a processor via a bank of strobed string encoder circuits in a second embodiment of the present invention.
DETAILED DESCRIPTION
In FIG. 1, the three-dimensional view shows a cutaway end portion of an elongated resilient stringless fingerboard controller according to the present invention in an illustrative embodiment. The fingerboard controller assembly 10 comprises a resilient fingerboard 12, shown facing upwardly, having a flat rear surface affixed to a flat front surface of an elongated rigid rear board 14, which may be made from a suitable material such as plastic or wood. The playing surface at the front of the resilient fingerboard 12 is configured with an array of parallel longitudinal predominantly raised string-faces 16 and transverse subdominantly raised fret-faces 18 each comprising a row of fret-face members extending between adjacent string-faces. Each fret-face 18 corresponds to a conventional fret, however the interfret spacing may be made equal and optimized to facilitate fingering in contrast to the unequal interfret spacing required in conventional stringed fingerboards which is strictly dictated by active string length demands. The playing surfaces of string-faces 16 and fret-faces 18 are made half round to simulate the playing "feel" of conventional strings and frets.
The entire resilient fingerboard 12 may be molded in one integral piece; alternatively it may be made in two or more portions separably joined so as to provide access to the sensors without removal of a portion attached to the rear board.
Embedded in the resilient fingerboard 12 are string sensors, each in the form of an elongated strip retained in a longitudinal channel running parallel beneath a corresponding string-face 16, and fret sensors, each extending across the fingerboard retained in a transverse channel substantially perpendicular to the string sensors, the fret sensors being located typically at playing domains between adjacent fret-faces. In FIG. 1, the approximate locations of the nearest fret sensor and string sensor, as projected to outer surfaces of fingerboard 12, are indicated by arrows 28' and 22' respectively.
Each cell 20 formed between intersecting string-faces 16 and fret-faces 18 may be occupied by a recessed flat surface, formed in the resilient material of fingerboard 12, adhesively attached to the front surface of the rigid rear board 14. Alternatively the cells 20 could be left open exposing the rear board surface.
Electrical wiring from the sensor strips may be routed along a channel provided in rear board 14 running longitudinally along a central region of the top surface, with the wiring exiting at one end in the form of a cable, as indicated, which may be fitted with a suitable plug for connection to encoding and processing equipment. Alternatively the wiring from the sensor strips could be set into one or more channels or grooves formed in the fingerboard 12, or could be formed as flat ribbon cable or conductors sandwiched between the fingerboard 12 and the rear board 14.
FIG. 2 shows a cross section of the fingerboard controller assembly 10 of FIG. 1, taken at axis 2--2' which is the location of the first fret sensor: between the first and second fret-faces. The string-faces 16 protrude as shown. Embedded in channels on the back of the fingerboard 12 under each string-face 16 and supported against the front surface of the rear board 14, is located a string sensor 22. Embedded in channels running parallel along each side of each string-face 16, a pair of string-bend sensors 24 and 26 each made responsive to side finger pressure applied to string-faces 16. Between each pair of fret-faces 18 is a fret sensor 28, set into a transverse channel in the fingerboard 12 running across in front of the string sensors 22. Sensors 22, 24, 26 and 28 are typically of a resilient structure having a pressure-sensitive resistive element sandwiched between a pair of longitudinal conductive contact strips bonded to opposite sides of the element.
Pitch is selected on any string-face by finger-pressing (or thumb-pressing) a playing domain of a string-face 16 between adjacent fret-faces 18 in a manner similar to that of conventional string playing technique. The playing domain is defined by the fingerboard structure as a portion of the interfret spacing along a string-face over which response to pressure occurs. Typically each playing domain occupies at least half of the interfret spacing.
In a preferred embodiment directed to two-handed tapping as taught on the Chapman Stick whereby the player's two hands engage the fingerboard from opposite sides, typically ten strings and twenty five frets are simulated, thus there are ten string sensors, twenty four fret sensors with the resultant two hundred and forty playing domains.
FIG. 3 is an enlargement of the portion of FIG. 2 within the dashed circle 30 showing the cross section of a string-face 16 at an intersection with a fret sensor 28 which is situated on top of an intersecting string sensor 22 such that both sensors are responsive to finger pressure applied onto string-face 16 since the stacked sensors are simultaneously constrained against the rear board 14.
The string-bend sensors 24 and 26, flanking the string-face 16, are made responsive to side pressure. Due to the resilience, a small amount of bending and deflection of string-face 16 occurs as indicated by the dashed outlines.
FIG. 4 is a simplified functional block diagram illustrating a parallel type sensor system within the resilient fingerboard assembly 12, for operation with a special encoder unit 32 followed by a processor 42.
Within the resilient fingerboard 12, indicated in dashed outline, the parallel-connected grid matrix of string sensors 22, bend sensors 24/26 and fret sensors 28 is illustrated. For simplicity and clarity, only the first, second and final one of the string columns and fret rows are shown, with the understanding that the three string columns shown represent a quantity of x similar string columns and the three fret sensor rows shown represent a quantity of y similar fret sensor rows.
Each of the sensor strips, 22, 24, 26 and 28 is seen to have two terminals: one connected to a common ground bus 34 and the other wired to a pin of a connector strip 36, which is connected to a corresponding connector strip 38 of encoder unit 32 via a multi-wire cable 40, indicated in the dashed ellipse. Via this cable 40, which may be a flat ribbon cable, each string sensor 22, associated pair of string-bend sensors 24 and 26, each fret sensor 28 and the common ground 34 are connected to the encoder 32.
Encoder 32 is specially designed to operate from the parallel connected input signals as shown and to provide a designated level of polyphony and other sophistication.
The encoder 32 should provide output in MIDI format, so that processor 42 may be selected from a wide variety of readily available MIDI-based electronic processing apparatus such as music synthesizers, tone generators and the like.
The techniques used within encoder 32 to realize particularly specified design objectives are well known to musical electronics designers. Typically the sensor elements are of the pressure sensitive resistive type: a current is passed through each sensor element, typically a direct current through a series resistor from a low voltage source in the order of 12 volts suppled from encoder 32; then as the resistance varies the resultant voltage variations are sensed as input to encoder 32, typically by a bank of voltage comparators.
Other suitable pressure sensitive materials could be utilized for forming the sensor elements, with appropriate modifications in the design of the transducing circuitry; for example, it is considered viable to utilize piezo film strips, which generate a transient voltage in response to applied pressure and are inherently velocity sensitive.
The particular configuration of encoder 32 and the extent to which the full capabilities of the fingerboard portion 12 are to be realized and exploited are matters of design choice, subject to the usual tradeoffs of cost, complexity and capability. Ideally there should be full string polyphony, i.e. the capability of independent play of all simulated strings simultaneously; this implies that for ten simulated strings, the encoder 32 and processor 42 would effectively provide ten fully independent channels and tone generators. As an example of a practical compromise, reducing the polyphony from this ideal to six or eight notes could be considered generally acceptable.
As the fingerboard controller is being played, each time a string-face is pressed at an interfret playing domain, encoder 32 senses the resultant simultaneous initial change of a string sensor voltage and a fret sensor voltage, and reads from that particular string and fret combination the particular value of pitch intended, typically formatted as the note of the half tone C scale and the octave. Then, in accordance with the finger velocity and pressure applied, amplitude information appears at both the corresponding string and the fret signal inputs. One of these, typically the string signal, is then analyzed by the encoder 32 for its key amplitude parameters from which MIDI code is generated for controlling the amplitude envelope of the synthesized version of the selected note. In a preferred embodiment, it is particularly desired to sense attack velocity: this may be realized by sensing amplitude in a comparator referenced at a second level somewhat greater than the initial level of pitch sensing and then utilizing the time delay between these two levels as the attack velocity parameter to be encoded and then sent by the encoder 32 to the processor 42 where this input attack information may be utilized to control the amplitude envelope of the resultant synthesized note in any desired manner. Alternatively, attack velocity could be sensed by two or more sets of sequential binary switch contacts provided at each playing domain, however this would greatly increase the bulk of multiple wiring required.
Sensed amplitude information may be translated into amplitude envelope shape according the well known ADSR parameters: attack, decay, sustain and release. Preferably, the sensed attack velocity is made to control the attack and decay of each note while continued fingertip pressure on the string-face, i.e. after-touch, is made to control the sustain and release of the note. Alternatively, in a simplified embodiment, sensing of attack and/or after-touch could be eliminated, and the envelope shaped according to a fixed or selectable ADSR setup.
Functionally, when amplitude information is sensed from the string sensors 22 as described above, the fret position sensor strips 28 are required to provide only a binary (on-off switch) function which is utilized for pitch determination, therefore the fret sensor function could be implemented as merely a pair of pressure-actuated switch contacts; however in the present embodiment the function is conveniently implemented as shown using a pressure-sensitive type resistive strip having a sufficiently high resistance differential to act as a "soft" switch whose point of actuation may be set by a comparator reference level at the input of encoder 32.
In the parallel system of FIG. 4 the actuation thresholds of the string sensors and the fret sensors at all of the playing domains must be closely matched to minimize the probability of errors in polyphonic performance, particularly when more than one fret-face is involved in a playing a chord of two or more notes practically simultaneously since correlating each string signal with the correct one of the fret signals relies on precise timing discrimination.
The string-bend sensors 24 and 26 operate in a manner similar to that described above for the string sensors: in FIG. 4, side pressure on the string-face associated with sensor 22 toward the left acts on sensor 24 to produce a signal voltage which is applied to the -(S1) terminal at the input receptacle 38 of encoder 32, while side pressure in the opposite direction acts on sensor 26 to produce a signal voltage which is applied to the +(S1) terminal. Encoder 38 may be set to provide a selection of different pitch-bend modes: in a unidirectional mode which simulates the upward pitch-bending of conventional guitar playing technique, the + and - signal inputs are processed in a manner to cause an increase in pitch when the string-face is pushed to either side. However in a preferred embodiment, encoder 32 is made to cause the string-bend sensors 24 and 26 to shift pitch in opposite directions to offer the player the capability of downward as well as upward pitch-bending and vibrato as a selectable option. In implementing bidirectional pitch-bending, a convention must be elected regarding the direction of pitch change resulting from a particular direction of stringface side pressure: in a preferred embodiment for two-handed tapping, as taught on the Chapman Stick whereby each hand engages the fingerboard from opposite sides, the pitch is made to increase in response to side pressure toward the center line of the fingerboard and conversely decrease in response to pressure toward either edge. As a benefit of the method of pitch bending taught in the present invention, the shift in pitch is inherently uniform with respect to the side thrust applied to the string-face at any point along the length of the fingerboard, whereas conventional guitar string-stretching technique requires the player to learn how to compensate for large variations in the amount of side pressure required due to inherent limitations and anomalies in the mechanics involved, particularly toward the "nut" end of the fingerboard. The ability of the present invention to bend pitch downward as well as upward eliminates the conventional need for a string tension lever and the need for a free hand to operate such a lever while playing.
FIG. 5 is a simplified functional block diagram showing, as an alternative embodiment to the circuit of FIG. 4, a series connected matrix system of string and fret sensors for selecting pitch. The pitch bend sensor strips 24 and 26 are connected to common ground 34, and operate in parallel.
Encoder 32A comprises a bank of individual string encoder modules 44 each connected to a corresponding string sensor and to all of the fret sensors. A strobe generator 46 provides a group of outputs each connected to the string signal input terminal of a string encoder module 44; these outputs are configured as sequential pulses, each having a duty factor of less than 1/x, where x is the number of simulated strings, so as to sequentially strobe the pulse voltages applied to the string sensors 22. At each intersection of a string sensor 22 and a fret sensor 28A the second terminal of the string sensors 22 is placed in contact with (or otherwise connected to) a short conductive segment on the fret sensor 28A as indicated.
Each fret input terminal of encoders 34 is made to have a predetermined input resistance value. When no string domains are pressed, the high resistance of the sensors limits the current in all branches such that the voltages developed at the fret inputs of encoders 44 are all below a predetermined threshold value, and consequently no input is sensed and no response occurs. When a string-face is depressed at a playing domain, compression of the two sensors at that domain results in a lower resistance thereby developing a signal voltage exceeding the threshold value on the corresponding fret input terminals of encoders 44. Each encoder 44 is commutated by the strobe pulses from strobe generator 46 so as to respond only to fret signals received from the corresponding string, so that each playing domain selected by pressure on a string-face is detected unambiguously, and from this information each encoder 44 determines the intended pitch and sends appropriate MIDI pitch information to the processor 42. Immediately following pitch selection, the fret signal provides amplitude information in the form of a real time analog envelope signal from which the encoder 44 can derive ongoing amplitude parameters and send the appropriate information to the processor 42 in the same manner as described above in connection with FIG. 4. Each encoder 44 receives the + and - pair of pitch-bend inputs and these are processed for pitch bending in the same manner as described above in connection with FIG. 4.
The contact segments on the fret sensors 28A at each intersection with a string sensor 22 are indicated as shown in FIG. 5 for clarity of explanation: in actual implementation these contact segments may be made much smaller or even eliminated as long as a portion of the fret sensor 28A is made to contact a point along the metallized full length contact strip of string sensor 22, at least when the string sensor receives finger pressure.
Since they are functionally segmented, the fret sensors 28A could be alternatively be implemented as a row of individual fret sensor segments, one at each string-face, with one terminal of each sensor segment connected to the common signal bus of that fret, according to the wiring as shown in heavy lines.
As another alternative, instead of being of pressure-sensitive resistive material, fret sensors 28A could be configured simply as conductive strips, held slightly separated from the string sensors 22 such that contact would occur only from finger pressure in a simple binary (off-on switch) action to determine pitch, whereupon the resistance variations and resultant sensed voltage variations originating in the string sensors 22 in response to pressure variations would provide amplitude envelope information to be acted upon by the corresponding encoder 44 as described above.
In any of the embodiments, two further dimensions of fingertip control may be implemented by incorporating fret-bend sensors, flanking each of the fret-faces, adapted to bidirectionally sense fingertip pressure applied to any fret-face along the direction of the string faces. These additional dimensions of fingertip control may be readily utilized to provide proportional control over additional parameters such as timbre, reverberation, echo effects, cross-faders, etc.
The embodiments described above are illustrative of preferred modes of making and practicing the present invention as directed to fully exploiting its advantages to facilitate playing music in a two-handed fingerboard mode, as practiced in connection with The Chapman Stick, and for this purpose is proposed as simulating ten strings along with twenty to twenty five frets.
The concept taught hereby is readily adaptable to any desired number of strings and frets. Many of the advantages of the present invention, particularly in regard to frequency selection and pitch bending, would also benefit the more conventional styles of one-handed fingering on a fretboard. For example, the principles described above are readily adaptable to realize a "six-string" version of the resilient fingerboard controller for either one-handed or two-handed fingering: some of the amplitude control capabilities enabled by this invention could be further modified by techniques customarily contributed by the other hand, or as an alternative the additional degree of control capability introduced by pressure sensitivity as taught by this invention could be utilized for controlling other musical parameters and effects chosen from the large menu available in present day MIDI/synthesizer technology.
As an alternative to the string-faces being raised further than the fret-faces as described above, all the string faces could be raised to a common level.
It would be possible to interchange the two planes in which the string-sensors and the fret-sensors are located between the fingerboard and the rear board since they would both sense applied finger pressure equally well either way.
As an alternative to locating fret sensors between fret-faces as described above, each fret sensor could be located immediately behind a corresponding fret-face. The fingerboard would be adapted to actuate two adjacent fret sensors when finger pressure is applied to the domain between the fret-faces, and the encoder would be adapted to sense the domain by sensing the actuation of the two fret-sensors.
A series type fingerboard controller embodiment may be made to have two-note polyphony on each string, in effect doubling the fingerboard playing area for a two-handed tapping method and allowing a reduction in the number of strings, for example from ten to six, which would accommodate conventional six string guitar techniques as well as the two-handed tapping techniques used by Stick players and by some guitarists.
A more simplified and economical version would utilize a parallel circuit embodiment to provide a "six string" version with two or four note overall polyphony, oriented generally to conventional playing techniques.
In a simplified embodiment requiring only the basic pitch selection and amplitude aspects of the invention, the pitch-bend sensors 24 and 26 (FIGS. 2, 3, 4 and 5) could be eliminated for simplicity and economy, and pitch bending could be implemented by alternate means such as a pitch bend wheel, lever or pedal.
A pair of fingerboards of this invention, each made shorter and with fewer frets, may be installed upon a single longer rear board structure adapted for the two-handed tapping technique, whereby a reduced number of string faces, for example simulating six guitar strings, is doubled in concept as the player uses two hands, one on each fingerboard.
The invention may be embodied and practiced in other specific forms without departing from the spirit and essential characteristics thereof. The present 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 by the foregoing description; and all variations, substitutions and changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
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Strings and frets are simulated in a resilient fingerboard controller for synthesizer-type musical instruments. Raised string-faces and fret-faces simulate the feel of conventional strings and frets. Embedded sensor strips connect to an external customized encoder. In operation, notes are selected in the manner of conventional guitar fret-stopping but with either hand or both hands simultaneously. The pitch of each note is under real time control of the player's finger tips via pressure exerted in either lateral direction against the simulated strings, bending the pitch upward in proportion to the amount of such pressure in either direction as is usual in stringed instruments, or, alternatively, bending the pitch up or down depending on the direction of the pressure. Optional fret-bend sensors enable proportional control over additional effects. A series-connected sensor matrix and a bank of individual strobed string-face encoders provide full all-string polyphony; alternatively, a parallel sensor matrix and multi-encoder may be made to provide a lesser degree of polyphony for simplification and economy. MIDI formatting of the encoder output provides wide compatibility with readily available musical equipment. The present invention provides special benefits when operated in conjunction with the two-handed tapping technique as practiced on the ten-string Chapman Stick* and The Grid*.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is based on provisional application No. 60/327,445 filed Oct. 5, 2001 and entitled “Oral Gastric lavage Kit With Matched Aspiration Stream Apertures” and claims the benefit thereof.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Field of the Invention
The present invention relates to a medical lavage apparatus and more particularly to an apparatus used for oral gastric lavage.
BACKGROUND OF THE INVENTION
Acute poisoning is a common cause of morbidity and mortality in children and adults. However, if ingested poison can be removed from the gastrointestinal track before being absorbed, the risk of severe poisoning is reduced. One method of removing ingested poison is that of oral gastric lavage in which the gastrointestinal track or stomach is successively irrigated and aspirated through a lavage tube inserted along the patient's gastrointestinal track to the stomach.
A common method of oral gastric lavage is described in U.S. Pat. No. 5,667,500 which uses parallel connected syringe cylinders having plungers and valves to allow both irrigation and aspiration through a single nozzle connected to a single lumen pliable lavage tube. Such a system requires continual, manual pumping by an attendant.
An improvement is taught in U.S. Pat. No. 5,890,516 which provides an aspiration valve allowing the use of an in-wall vacuum system, such as is commonly found in hospitals, for operation of the lavage system without manual pumping. In this device, a double lumen flexible tube is provided, one lumen delivering an irrigation liquid and the second being used for aspiration through the in-wall vacuum system. The aspiration valve allows continual adjustment of the aspiration pressure.
A problem plaguing all oral gastric lavage systems is clogging of the lavage apparatus, for example, from pill fragments contained in the patient's stomach. A number of methods have been used to attempt to reduce this problem. The above referenced U.S. Pat. No. 5,667,500 describes the use of special, large size, slit valves and back flushing of the lumen tube with irrigant, a procedure not available with the more convenient dual lumen design. U.S. Pat. No. 5,890,516 provides the aspiration valve with a funnel-shaped connector tapering smoothly to a sharp lip to reduce the possibility of particles becoming lodged at the interface between the aspiration valve and a dual lumen lavage tube.
These solutions are not wholly satisfactory and clogging of lavage systems is still common.
BRIEF SUMMARY OF THE INVENTION
The present inventors have recognized that clogging, particularly in the dual lumen design, can be significantly reduced by matching the components together in a single kit. Key to the matching is that the diameter of connections of all successive portions of the aspiration path from the distal portion of the lavage tube to the inlet to the collection vessel attached to the in-wall vacuum system must be greater than or equal to the diameter of the initial inlet apertures of the distal portion of the lavage tube. The potential for clogging may be thereby moved to the interface between the distal portion of the lavage tube and the stomach where the inventors believe that the multiple apertures, better accommodate some clogging without significant effect, and where clogging fragments may be more easily dislodged with the cessation of aspiration pressure. The inventors have further recognized that in the real world hospital environment, proper operation of the oral gastric lavage system requires that the components of the system be pre-collected in a single location and pre-selected to work together. Accordingly a kit containing all the components necessary for oral gastric lavage in a single package is highly desirable, even though many of the components are multi-use products generally available in a hospital environment and could be obtained if not in such a kit.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of components of the oral gastric lavage kit of the present invention showing the in-wall vacuum system and its collection vessel, the aspiration valve, the dual lumen lavage tube, the irrigation bag, and other components;
FIG. 2 is a cross-sectional view of the aspiration valve showing the key internal diameters;
FIG. 3 is a fragmentary perspective view of the aspiration valve of FIG. 1 showing the introduction of an improved sealing ridge around the bleed air inlet;
FIG. 4 is a fragmentary view of the distal end of the dual lumen lavage tube showing its key dimensions; and
FIG. 5 is a plot of internal diameters plotted against distance along the aspiration path of the kit of FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1 , an oral gastric lavage kit 10 of the present invention, such as may be collected and sealed in a plastic pouch 11 , is adapted for use with an in-line vacuum system 12 providing a vacuum line 14 received by a collection vessel 16 to draw air therefrom.
The collection vessel 16 serves as a trap for receiving solids and liquids drawn through inlet 18 , the latter which may be connected to vacuum tube 20 to provide a flexible source of suction for hospital procedures. The inlet 18 provides the last restriction through which material collected from the gastrointestinal track must pass before reaching the collection vessel 16 and present an opening size 22 a that remains relatively standard from hospital to hospital.
In an alternative embodiment (not shown), the kit 10 includes a collapsible collection vessel that may be attached upstream of the vacuum tube 20 to reduce the transport distances required of pumped material. In this case, collection vessel 16 is not required and vacuum tube 20 is attached directly to the in-line vacuum system 12 .
The vacuum tube 20 will have an internal diameter of greater than this opening size 22 a of the inlet 18 as it fits over the outside of the inlet 18 . The present invention provides a kit including this vacuum tube 20 and additional components as will be described. The vacuum tube 20 may include a vortex device 21 (shown in FIG. 1 ) such as a “corkscrew” spiral made by an internal groove causing a vortex flow of liquid in the vacuum tube 20 placed near the inlet 18 . The vortex device improves the flow of air and liquid. On the distal end of the vacuum tube 20 , a corrugated elbow 23 is used to prevent kinking.
Referring now also to FIG. 2 , the oral gastric lavage kit 10 further includes an aspiration valve 24 providing for upstream control of the pressure of the vacuum to an amount less than that present at the vacuum tube 20 . Generally, the aspiration valve 24 provides a step-tapered end 26 receiving the vacuum tube 20 by interference fit of the inner diameter of the vacuum tube 20 against an outer ridged surface of the step-tapered end 26 . The aspiration valve 24 provides a conically expanding central channel through the aspiration valve 24 to an opposite flare end 35 which may receive the oral gastric lavage tube 40 . Notably, the flare end 35 of the aspiration valve 24 opposite the step tapered end 26 provides for a thin lip 30 that may fit snugly against the inside of the oral gastric lavage tube 40 to provide a relatively smooth inner wall transition from oral gastric lavage tube 40 to the inner passage 29 thus minimizing the change of particles and the like catching and clogging the pathway. The principal features of this valve are described in U.S. Pat. No. 5,890,516, hereby incorporated by reference.
The opening size 22 b of the step tapered end 26 and the opening size 22 c of the flare end 35 of the aspiration valve 24 are selected to be no smaller than the size 22 e of the distal portion of the oral gastric lavage tube 40 as will be described below.
The aspiration valve 24 includes a bleed-air inlet 34 allowing ingress of air to reduce the suction drawn on the oral gastric lavage tube 40 . Air flow through the bleed-air inlet 34 may be controlled by sliding inlet cover 36 which may be moved to variably occlude the bleed air inlet port 34 .
Referring to FIG. 3 , the valve described in the aforementioned '516 patent is modified over that description by the introduction of a sealing ridge 38 around the bleed-air inlet 34 providing improved sealing and retention of the sliding inlet cover 36 .
Referring now to FIGS. 1 and 4 , the oral gastric lavage tube 40 may be a coaxial tube including an outer lumen 41 for aspiration and an inner lumen 42 for irrigation. Dual lumen gastrointestinal tubes may be obtained from Mallinckrodt under the trade name Lavacuator gastrointestinal tube and are available in sizes 18, 22, 28, 32, and 36 French and in length 48 inches. Preferably, however, the oral gastric lavage tube 40 would have an inner diameter of 34 French. The oral gastric lavage tube 40 may include a radio opaque stripe 43 to assist in location of the tube under fluoroscopic examination and may include graduations 47 in centimeters together with centimeter numbers to assist the attending physician in placement of the oral gastric lavage tube 40 in the gastrointestinal tract.
The inner lumen 42 may terminate at a proximal end with a funnel connector 44 to be received by corresponding cone connector 46 of connector line 49 of a 3500 cc irrigation bag 50 . The connector line may include a ratchet clamp 52 for metering the irrigant flow. The irrigation bag 50 provides a cap 54 and hanger 56 for suspension on an IV pole according to techniques well known in the art.
Referring to FIG. 4 , the outer lavage tube includes a number of eye holes 58 at its distal end 45 . The inner lumen 42 which is adhered to one wall of the outer lumen 41 is terminated at the distal end 45 and has much smaller eye holes 63 for providing irrigation fluid from the irrigation bag 50 .
Referring to FIGS. 1 and 5 , the eye holes 58 are elliptical in shape and have size 22 e less than the sizes 22 a - 22 d as measured by the minor diameter of the ellipse of the eye holes 58 and preferably a size of 20 French. An open end 61 of the oral gastric lavage tube 40 may be sealed or may be left open provided its diameter is less than sizes 22 a - 22 d as described above. By incorporating the vacuum tube 20 , the aspiration valve 24 , and oral gastric lavage tube 40 into one kit, the relative sizes of the eye holes 58 and of all intervening restrictions 22 a - 22 d may be controlled so as to significantly reduce clogging in a dual lumen system.
As a matter of convenience, the oral gastric lavage kit 10 may also include other convenient elements including a bite block 60 of the style that is commercially available in the art, a biohazard bag 62 for disposal of the lavage kit when complete, a 140 cc syringe 64 with a 34 French tip for introducing the charcoal suspension and injecting air into the lavage tube 40 for placement verification with a stethoscope. The irrigation bag 50 and its associated parts are included to ensure compatibility with the desired oral gastric lavage tube 40 . The kit may also include a lubricant 68 for lubricating the oral gastric lavage tube 40 for insertion into the GI track. Alternatively, the oral gastric lavage tube 40 may be precoated with a commercially available hydrophilic coating that becomes lubricious when made wet such as is manufactured by Hydromer of Somerville, N.J. and others.
Other elements of the oral gastric lavage kit 10 may include a container of activated charcoal suspension 66 such as is commercially available, sorbitol 71 , a disposable gown 69 , and an emesis bag 70 . Separate sorbitol and charcoal containers are provided to allow the attending physician to elect not to use the sorbitol while still using the charcoal.
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A kit includes all the materials necessary for oral gastric lavage in a single pouch. The components, many of which are common hospital supplies, may thus be pre-selected to work together in critical applications and to resist clogging.
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FIELD OF THE INVENTION
[0001] The present invention relates generally to computer software development, and specifically to tracking the amount of memory allocated by a software program.
BACKGROUND OF THE INVENTION
[0002] In early programming languages, memory allocation and deallocation was a burden imposed directly on the programmer, who was responsible for allocating and deallocating memory blocks. This burden was eased by the introduction of garbage collectors, which are programs that deallocate memory that is assigned to dead or unreachable objects. Garbage collectors have improved programmer productivity and have enhanced software reliability. They are supported by a variety of modern programming languages, such as Java™.
[0003] The Java Virtual Machine Profiler Interface (JVMPI) is a two-way function call interface between the Java virtual machine and an in-process profiler agent. The profiler agent issues controls and requests for information through the JVMPI. In response, the virtual machine notifies the profiler agent of various events, corresponding, for example, to heap allocation, thread start, etc. The JVMPI can be used by profiling tools to obtain information on memory allocation sites, CPU usage hot-spots, unnecessary object retention, and monitor contention. JVMPI is available from Sun Microsystems (Palo Alto, Calif.) and is described at java.sun.com/j2se/1.4.2/docs/guide/jvmpi/jvmpi.html.
SUMMARY OF THE INVENTION
[0004] As supported in most languages, garbage collection is an asynchronous process. It is typically invoked automatically by the computer system at runtime when the amount of memory allocated by the running program reaches some limit, which depends on the amount of memory actually available in the system. The developer is generally unable to determine at any particular point in the execution of the application how many memory objects and how much total memory have actually been allocated. Excessive memory allocation will lead to long and frequent garbage collection, which may in turn degrade the performance of the application.
[0005] Embodiments of the present invention address this problem by providing the software developer with tools that can be used to track and visualize allocation of memory objects in a software program. For this purpose, a profiler collects records of memory allocations during a trial run of the program. This step generates a large volume of data, since a typical program may create thousands or even millions of objects during even a short run. Therefore, in embodiments of the present invention, the records are sorted and aggregated so as to permit the developer to see the amount of allocation that occurred at each point in the program and, typically, to bring out the most allocation-intensive program lines. The aggregated records may also include stack traces, to enable the programmer to observe the sequence of program steps leading up to points of heavy allocation. This presentation of information enables the programmer to identify, understand and debug the points of excessive memory allocation in the program.
[0006] In some embodiments, the aggregated records are stored in a relational database. The programmer can then query the database using a suitable browser.
[0007] Although the embodiments described hereinbelow relate specifically to Java programming and use Java profiling tools, the principles of the present invention may similarly be applied to track memory allocation in other programming environments.
[0008] There is therefore provided, in accordance with an embodiment of the present invention, a method for assessing memory use of a software program, the method including:
[0009] collecting records of memory allocations while running the program, the records indicating respective allocation points in the program;
[0010] sorting the records according to the respective allocation points; and
[0011] displaying the sorted records so as to enable a user to observe totals of the memory allocations at the respective allocation points.
[0012] In a disclosed embodiment, collecting the records includes applying a profiling agent to receive allocation events while the program is running.
[0013] In some embodiments, collecting the records includes collecting stack traces at the allocation points, and displaying the sorted records includes displaying information regarding the stack traces for at least some of the allocation points. Typically, sorting the records includes sorting the records belonging to a given allocation point according to entries in the stack traces leading to the given allocation point. In one embodiment, displaying the sorted records includes displaying the records in a hierarchical representation having a root at the given allocation point and branches corresponding to the entries in the stack traces. Additionally or alternatively, displaying the sorted records includes displaying, together with the entries in the stack traces, the respective subtotals of the totals of the memory allocations at the given allocation point.
[0014] Further additionally or alternatively, sorting the records includes defining first and second groups of the allocation points according to the totals of the memory allocations, and displaying the information includes displaying the stack traces up to a first trace depth for the first group and up to a second trace depth, less than the first trace depth, for the second group.
[0015] In disclosed embodiments, sorting the records includes aggregating the records so as to compute, for each of at least some of the allocation points, a total number of objects allocated and a total volume of the memory allocate on all passes through the allocation points while running the program.
[0016] In an alternative embodiment, displaying the sorted records includes displaying respective class and method names of the allocation points. In this embodiment, displaying the sorted records typically includes grouping the records for display according to the class.
[0017] There is also provided, in accordance with an embodiment of the present invention, apparatus for assessing memory use of a software program, the apparatus including:
[0018] a processor, which is arranged to collect records of memory allocations while running the program, the records indicating respective allocation points in the program, and to sort the records according to the respective allocation points; and
[0019] an output device, which is coupled to be driven by the processor to display the sorted records so as to enable a user to observe totals of the memory allocations at the respective allocation points.
[0020] There is additionally provided, in accordance with an embodiment of the present invention, a computer software product for assessing memory use of a software program, the product including a computer-readable medium in which program instructions are stored, which instructions, when read by a computer, cause the computer to collect records of memory allocations while running the program, the records indicating respective allocation points in the program, to sort the records according to the respective allocation points, and to display the sorted records so as to enable a user to observe totals of the memory allocations at the respective allocation points.
[0021] The present invention will be more fully understood from the following detailed description of the embodiments thereof, taken together with the drawings in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is a schematic, pictorial illustration of a system for software development, in accordance with an embodiment of the present invention;
[0023] FIG. 2 is a flow chart that schematically illustrates a method for tracking and visualizing memory allocations in a software program, in accordance with an embodiment of the present invention;
[0024] FIG. 3 is a flow chart that schematically illustrates a method for sorting records of memory allocations, in accordance with an embodiment of the present invention; and
[0025] FIGS. 4 and 5 are schematic representations of a user interface for visualizing memory allocation points, in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF EMBODIMENTS
[0026] FIG. 1 is a schematic, pictorial illustration of a system 20 for software development, in accordance with an embodiment of the present invention. The system is used by a programmer 22 to run and debug a software program under development, such as a Java application. Typically, the system is built around a computer processor 24 , which is programmed in software to carry out the functions described hereinbelow. This software may be downloaded to system 20 in electronic form, over a network, for example, or it may be furnished on tangible media, such as optical, magnetic or electronic memory.
[0027] The operation of system 20 is described in detail hereinbelow with reference to the figures that follow. Briefly, processor 24 runs the program under test and records memory allocations that occur during the program. These records are sorted, aggregated and then stored in a database in a memory 26 . Alternatively, other sorts of data structures, as are known in the art, may be used to hold the results. Programmer 22 can then query and browse the results in the database using a suitable output device 28 , such as a computer monitor. In this manner, the programmer is able to identify and understand points of excessive memory allocation in the program under development. The programmer may then revise the software code to enhance the memory-efficiency of the program, and then may run the program again in system 20 until the desired results are achieved.
[0028] FIG. 2 is a flow chart that schematically illustrates a method for tracking and visualizing memory allocations using system 20 , in accordance with an embodiment of the present invention. The method uses the JVMPI, as described above, which notifies a specified profiler agent of certain specified events that occur during running of the program under test. As defined in the JVMPI specification, the agent is a dynamic link library (DLL)/shared object, which is loaded by the Java Virtual Machine (VM) in response to an appropriate Java command. Arguments of the command specify the name of the agent to load. The agent is a software routine written in native code, such as C or C++, which runs on processor 24 together with the program under test. The agent registers events in the VM that are reported via the JVMPI.
[0029] The profiler agent is initialized by the Java VM, at an agent initialization step 30 . The agent specifies the types of events that should be reported to it by calling the JVMPI method RequestEvent. To trace object allocations, the agent requests that the JVMPI report JVMPI_EVENT_OBJECT_ALLOC events, which causes the JVMPI to report all allocations. In the present embodiment, the request is accompanied by the interface function JVMPI_CallTrace, which causes the JVMPI to output a stack trace of the thread that performed the allocation together with each allocation event. (Generating a trace for every memory allocation in this manner produces a very large volume of information, which is then organized using the methods described hereinbelow so that the programmer will be able to use the information.) The agent indicates the length of the stack trace (i.e., the number of frames in the trace) to be reported. The programmer may specify the desired length, based on a heuristic tradeoff between the amount of information provided for each allocation and the memory and processing limitations of processor 24 . The programmer may also specify filters, so that the JVMPI reports only those allocation events that meet certain criteria. For example, the JVMPI may be instructed to report only events that originate from a specified class name. Alternatively or additionally, the agent may be programmed to filter the events it receives and to record only those events that meet certain filtering criteria.
[0030] Processor 24 runs the program under test, at a run step 32 . For every allocation reported by the JVMPI during the run, the profiler agent creates a record containing the allocation information, such as the object size and the type of object, if provided, and the stack trace. The JVMPI represents each frame in the stack trace as a pair of long numbers: <method ID, line number>. These numbers may be resolved to give the class name and method name, but the resolution is typically delayed to a later stage in order to improve the performance of step 32 . Step 32 may continue until the program under test finishes running. Alternatively, the agent may be instructed to start and stop collecting allocation information at desired points during execution of the program under test, without necessarily exiting or restarting the program. The agent may have a suitable interface, such as a Telnet interface, that permits this sort of remote control.
[0031] The result of step 32 is a long list of allocations in order of occurrence. In order to present the allocation information in a way that is useful to programmer 22 , processor 24 sorts the allocation records by allocation point, at a sorting step 34 . (The “allocation point” of a given allocation is the line in the program at which the allocation event occurred.)
[0032] For example, assume the following records were accumulated at step 32 :
TABLE I UNSORTED ALLOCATION RECORDS # alloc. size depth = 0 depth = 1 depth = 2 depth = 3 1 10 <125, 10> <2534, 20> <4350, 30> <150, 40> 2 10 <400, 45> <1333, 40> — — 3 10 <125, 10> <2522, 25> <233, 50> <250, 40> 4 10 <400, 42> <455, 40> <546, 66> <666, 76> 5 15 <125, 10> <2534, 20> <555, 88> <987, 44>
[0033] In this table, the “depth=0” entries represent the allocation points, listed by <method ID, line number>. The subsequent entries in each row are the succeeding elements in the stack trace for the allocation event in question. The allocation records are sorted at step 34 by method ID and line number beginning from the allocation point and then moving down the stack traces. In other words, first the records are grouped by the depth=0 values. Within these groups, the records are grouped by the depth=1 values, and so forth up to the maximum recorded depth:
TABLE II SORTED ALLOCATION RECORDS # alloc. size depth = 0 depth = 1 depth = 2 depth = 3 1 10 <125, 10> <2522, 25> <233, 50> <250, 40> 2 15 <125, 10> <2534, 20> <555, 88> <987, 44> 3 10 <125, 10> <2534, 20> <4350, 30> <150, 40> 4 10 <400, 42> <455, 40> <546, 66> <666, 76> 5 10 <400, 45> <1333, 40> — —
[0034] The volume of the recorded data, however, is still very large. To reduce the data volume and enhance performance of present debugging tool, the results may be further sorted by the amount of memory allocation at each allocation point. For each allocation point, the total allocation is determined by summing the allocation size over all the records belonging to this allocation point. The full stack trace is then saved only for the “top N” allocation points, i.e., the N allocation points with the greatest total allocation size and/or greatest total number of allocation events. The value of N may be configured by programmer 22 . For the remaining allocation points, only an abbreviated stack trace (which may be abbreviated down to no stack trace at all) is saved.
[0035] Further details of the sort procedures carried out at step 34 are described hereinbelow with reference to FIG. 3 . A source code listing of a procedure that can be used for record sorting at step 34 is given below in Appendix A.
[0036] Processor 24 next aggregates the records that have the same allocation point in order to give a consolidated view of the allocations, at an aggregation step 36 . In this view, each stack entry in the sorted allocation list above is listed along with its cardinality (i.e., the number of allocation events, which is equal to the number of consecutive occurrences of the entry in the sorted list) and the total allocation of all these occurrences:
TABLE III AGGREGATED ALLOCATION RECORDS from to alloc. size 1 3 35 <125, 10> *3 1 1 10 <2522, 25> 1 1 10 <233, 50> 1 1 10 <250, 40> 2 3 25 <2534, 20> *2 2 2 15 <555, 88> 2 2 15 <987, 44> 3 3 10 <4530, 30> 3 3 10 <150, 40> 4 5 20 <400, 42> *2 4 4 10 <455, 40> 4 4 10 <546, 66> 4 4 10 <666, 76> 5 5 10 <1333, 40>
In the above table, the columns “from” and “to” refer to the numbers of the corresponding rows in Table II, while the figures marked with “*” following certain <method ID, line number> pairs indicate the cardinality of the corresponding entries. This information is useful subsequently in browsing through the results and associating the aggregated records with the raw event listings.
[0037] Processor 24 now stores the aggregated records in a database file on storage device 26 , at a storage step 38 . In practice, the aggregation of results in step 36 is done implicitly while printing the results to a disk-file in step 38 . During step 38 , the method ID and line number of each record are translated into the appropriate <class name>.<method name>. The profiler agent obtains the class name corresponding to each method ID by invoking the RequestEvent method to ask the JVMPI to report JVMPI_EVENT_CLASS_LOAD events. The agent caches the loaded classes in its memory to avoid having to ask for the same class name multiple times.
[0038] Each record in the database created in storage device 26 at step 38 contains the following fields, corresponding to the elements of the aggregated record list generated at step 36 (as illustrated above in Table III):
TABLE IV ALLOCATION DATABASE Field Meaning UID int - A unique ID assigned to each record PID int - UID of the record that is the parent of this record (or 0 for allocation points) AID int - The UID of the allocation point for a stack trace (for allocation points AID = UID) SCENARIO_NAME varchar(20) - Allows more than one scenario per table START_ID int - See Table III: from END_ID int - See Table III: to SEQ int - The stack depth CLASS varchar(250) - The Java class name (including the package) METHOD varchar(50) - The Java method name LINE int - The line number in the Java code TYPE varchar(20) - The type of object allocated (int, char, char[ ], object, etc.) ALLOC_CLASS varchar(250) - The class name, if type is object TIMES int - the cardinality of this allocation/ stack trace SIZE bigint - The sum of memory allocated in this allocation point/stack trace
[0039] After organizing the allocation records in the database in the manner, the results are ready for browsing by programmer 22 , at a browsing step 40 . The browser screen on output device 28 typically uses a nested hierarchical display model, as shown in FIGS. 4 and 5 below. The programmer may select the records to view using a suitable query language, such as SQL.
[0040] FIG. 3 is a flow chart that schematically shows details of sorting step 34 , in accordance with an embodiment of the present invention. As noted above, processor 24 sorts the records by allocation point, at an allocation sorting step 50 . It then sorts the records for each allocation point by the successive stack trace entries, in order of increases depth within the stack, at a stack sorting step 52 . Appendix A shows an exemplary implementation of these steps.
[0041] Next, processor 24 identifies the top N allocation points, i.e., a certain number (N) of lines in the program that have the largest cumulative allocations. To identify the top N, the processor begins by putting the first N allocation points from the list generated at step 50 into a “top N” array, at an initial ranking step 54 . For each allocation point, the processor calculates the total allocation of memory over all occurrences of the allocation point (corresponding to the “alloc. size” field in Table III).
[0042] The processor then proceeds to the next allocation point in the list, at a next point test step 56 . If the total memory allocation at the next allocation point is less than the total allocation of any of the top N, the processor makes no change in the top N listing, but simply checks whether any more allocation points remain to be evaluated, at a termination checking step 58 . On the other hand, if the total memory allocation at the next allocation point is greater than at least one of the top N, this allocation point is inserted into the top N array, at a top N replacement step 60 . The current member of the top N with the lowest total memory allocation is concurrently removed from the top N. As noted earlier, processor 24 may be configured to save long stack traces for the top N allocation points, and shorter stack traces (possibly down to zero length) for the remaining allocation points. The entries in the stack traces of the allocation points that are removed from the top N are therefore deleted down to this shorter length, at a trace cutting step 62 . The process continues in this manner through step 58 until all allocation points have been evaluated.
[0043] After choosing in this manner the allocation points that are to be ranked in the top N, processor 24 saves long stack traces of these allocation points, at a stack saving step 64 . The processor saves shorter stack traces for the remaining allocation points.
[0044] FIG. 4 is a schematic representation of a browser screen 70 , which is used to display the memory allocation results in the database at step 40 , in accordance with an embodiment of the present invention. Each allocation point 72 appears as the root of a hierarchical tree, with branches 73 corresponding to the succeeding entries in the stack traces that terminate on the allocation point. Each row in screen 70 corresponds to a row in the aggregated data view, as exemplified in Table III above. The user may select the “+” and “−” symbols at the left of each row to hide or reveal the branches below it in the hierarchy.
[0045] Each row in screen 70 corresponds to a line in the program under test. Each row begins with a cardinality 74 and a data size 76 . These figures correspond respectively to the cardinality and alloc. size fields in the aggregated data view of Table III. Thus, for allocation points 72 , the cardinality and data size indicate the number of allocations (objects) and total size of the objects allocated at the data point. For branches 73 , these figures indicate the number of times the program flow passed through the corresponding program line on the way to allocation at the root allocation point and the total size of the objects that were allocated as a result. In other words, in each of branches 73 , cardinality 74 and data size 76 represent the subtotals for this branch of the total number and size of allocations at the root allocation point. It may thus be observed that of the 516 objects, totaling 99.1 kb, that were allocated at the line represented by the first row in screen 70 , nearly half the total (226 objects, totaling 43.4 kb) resulted from program flows that passed through the line represented by the fourth row in the table. Programmer 22 may thus identify memory-intensive parts of the program flow and may use this information to identify and debug problematic sequences of steps in the program.
[0046] Each row in the screen is further identified by a class 78 and a method name 80 . A line number 82 indicates the line in the Java code. For allocation points, an object type 84 gives the type of object that was allocated by this line.
[0047] FIG. 5 is a schematic representation of a browser screen 90 that gives a different view of the results in the database, in accordance with another embodiment of the present invention. This screen is also invoked by an appropriate query to the database. In this case, the roots of the tree are classes 92 , which are identified by class names 94 . Cardinality 74 and data size 76 indicate the number and volume of memory allocations made from this class. Allocation points 72 themselves appear as leaves of the tree. This display allows the programmer to identify and debug the classes that are responsible for large amounts of allocation.
[0048] Other modes of display and details that may be collected and added to the database and display, regarding memory allocation points and their stack traces, will be apparent to those skilled in the art and are considered to be within the scope of the present invention. More generally, although the examples described above relate specifically to Java, the principles of the present invention may similarly be applied in creating software development and debugging tools for other object-oriented languages, particularly languages that use garbage collection.
[0049] It will thus be appreciated that the embodiments described above are cited by way of example, and that the present invention is not limited to what has been particularly shown and described hereinabove. Rather, the scope of the present invention includes both combinations and subcombinations of the various features described hereinabove, as well as variations and modifications thereof which would occur to persons skilled in the art upon reading the foregoing description and which are not disclosed in the prior art.
APPENDIX A “QUICK SORT” In one embodiment, record sorting at step 34 (FIG. 2) uses the quick sort algorithm, which is defined as follows: qsort(traceArray, arraySize, sizeof(MyCallTrace*), CompareTraces); traceArray - array of all records of allocations (array of MyCallTrace) arraySize - size of the array sizeof(MyCallTrace*) - size of each element in the array CompareTraces - method for comparing to records, as follows: int CompareTraces(const void * a, const void * b) { MyCallTrace *t1 = *(MyCallTrace**)a; MyCallTrace *t2 = *(MyCallTrace**)b; long mid,lnum; short minDepth = t1->num_frames < t2->num_frames? t1->num_frames : t2->num_frames; for (short depth = 0;depth < minDepth;depth ++) { mid = (long)t1->frames[depth].method_id − (long)t2->frames[depth].method_id; lnum = t1->frames[depth].lineno − t2- >frames[depth].lineno; if (mid < 0 || (mid == 0 && lnum < 0)) { return −1; } else if (mid > 0 || (mid == 0 && lnum > 0)) { return 1; } } return (t1->num_frames − t2->num_frames); } MyCallTrace is a structure that contains the record of each allocation: struct MyCallTrace { // number of frames in this trace jint num_frames; // stack frames -defined by JVMPI <line number, method id> JVMPI_CallFrame *frames; // a structure describing the allocated object (size, isArray, class, obj_id etc.) my_obj_alloc obj_alloc; // a flag that indicates whether this record belongs to the top N allocation points) bool isTopN; };
[0050]
APPENDIX B
AGGREGATION
In one embodiment, aggregation at step 36 uses the
following recursive algorithm, which is performed while
printing the results to the disk-file at atep 38:
Iterate over the traceArray (array of sorted records of
allocations) .
For each record, call the printEntry method:
Long PrintEntry(traceArray, currentIndex,
recursionDepth, arraySize, maxTraceDepth)
traceArray - array of records
recursionDepth - used for indentation in the file, for a
readable file format
arraySize - number of allocation records
maxTraceDepth - at each call to printEntry, the max stack
trace depth is defined. This feature may be used to
create different trace depths for the top N
allocation points.
The return value, long, indicates how many records were
aggregated
and should be skipped in the array.
long PrintEntry(traceArray, currentIndex, recursionDepth,
arraySize, maxTraceDepth)
{
If (recursionDepth >= traceArray[currentIndex]->num_frames
Return 1;
long skipNum = 1;
long memory = traceArray[currentIndex]->obj_alloc.size;
for (long compactIndex = currentIndex + 1;compactIndex <
arraySize;compactIndex++)
{
if (recursionDepth <= gTrace[compactIndex]->num_frames &&
traceArray[index]->frames[depth].method_id ==
traceArray[compactIndex]->frames[depth].method_id &&
traceArray[compactIndex]->frames[depth].lineno ==
traceArray[compactIndex]->frames[depth].lineno)
{
//same trace line
skipNum++;
memory += traceArray[compactIndex]->obj_alloc.size;
}
else
{
break;
}
}
if (depth == 0)
//...Print the record ‘traceArray[compactIndex]’ to the
file as allocation point
else
//...Print the record ‘traceArray[compactIndex]’ to the
file as stack trace, with indentation
if (maxTraceDepth < 0 || recursionDepth < maxTraceDepth)
{
long inIndex = compactIndex;
while (inIndex < compactIndex + skipNum)
{
inIndex += PrintEntry(inIndex, recursionDepth + 1,
compactIndex + skipNum, maxTraceDepth);
}
}
return skipNum;
}
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A method for assessing memory use of a software program includes collecting records of memory allocations while running the program, the records indicating respective allocation points in the program. The records are sorted according to the respective allocation points, and the sorted records are displayed so as to enable a user to observe totals of the memory allocations at the respective allocation points. In a disclosed embodiment, stack traces are collected at the allocation points, and information regarding the stack traces is displayed for at least some of the allocation points.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This Application is a national phase filing under 35 U.S.C. §371 of international application number PCT/US2005/033050, filed Sep. 16, 2005, which claims priority from U.S. Provisional Application No. 60/610,796, filed Sep. 17, 2004. The entire content of the prior applications are incorporated herein by reference in their entirety.
STATEMENT AS TO FEDERALLY SPONSORED RESEARCH
Funds used to support some of the studies disclosed herein were provided by grant number NIH NS 44829 awarded by the National Institutes of Health. The Government may have certain rights in the invention.
FIELD
The subject matter provided herein relates to compounds, composition and methods of inhibiting α-synuclein toxicity. In one embodiment, the compounds are benzothiazolyl, benzoxazolyl and benzimidazolyl guanidines, benzimidazolyl hydrazones, benzodihydropyridones, dihydropyridones, thienyl styryl ketones and N-benzimidazolyl-aminopyrazoles. In another embodiment, the compounds are used in methods of treatment of α-synuclein fibril mediated diseases, such as Parkinson's disease.
BACKGROUND
Parkinson's disease is a neurodegenerative disorder that is pathologically characterized by the presence of intracytoplasmic Lewy bodies (Lewy in Handbuch der Neurologie , M. Lewandowsld, ed., Springer, Berlin, pp. 920-933, 1912; Pollanen et al., J. Neuropath. Exp. Neurol. 52:183-191, 1993), the major components of which are filaments consisting of α-synuclein (Spillantini et al., Proc. Natl. Acad. Sci. USA 95:6469-6473, 1998; Arai et al., Neurosci. Lett. 259:83-86, 1999), an 140-amino acid protein (Ueda et al., Proc. Natl. Acad. Sci. USA 90:11282-11286, 1993). Two dominant mutations in α-synuclein causing familial early onset Parlinson's disease have been described suggesting that Lewy bodies contribute mechanistically to the degeneration of neurons in Parkinson's disease and related disorders (Polymeropoulos et al., Science 276:2045-2047, 1997; Kruger et al., Nature Genet. 18:106-108, 1998; Zarranz et al., Ann. Neurol. 55:164-173, 2004). Triplication and duplication mutation of the α-synuclein gene have been linked to early-onset of Parkinson's disease (Singleton et al., Science 302:841, 2003; Chartier-Harlin at al. Lancet 364:1167-1169, 2004; Ibanez et al., Lancet 364:1169-1171, 2004). In vitro studies have demonstrated that recombinant α-synuclein can indeed form Lewy body-like fibrils (Conway et al., Nature Med. 4:1318-1320, 1998; Hashimoto et al., Brain Res. 799:301-306, 1998; Nahri et al., J. Biol. Chem. 274:9843-9846, 1999). Both Parkinson's disease-linked α-synuclein mutations accelerate this aggregation process, demonstrating that such in vitro studies may have relevance for Parkinson's disease pathogenesis. Alpha-synuclein aggregation and fibril formation fulfills of the criteria of a nucleation-dependent polymerization process (Wood et al., J. Biol. Chem. 274:19509-19512, 1999). In this regard α-synuclein fibril formation resembles that of Alzheimer's β-amyloid protein (Aβ) fibrils. Alpha-synuclein recombinant protein, and non-Aβ component (known as NAC), which is a 35-amino acid peptide fragment of α-synuclein, both have the ability to form fibrils when incubated at 37° C., and are positive with amyloid stains such as Congo red (demonstrating a red/green birefringence when viewed under polarized light) and Thioflavin S (demonstrating positive fluorescence) (Hashimoto et al., Brain Res. 799:301-306, 1998; Ueda et al., Proc. Natl. Acad. Sci. USA 90:11282-11286, 1993).
Synucleins are a family of small, presynaptic neuronal proteins composed of α-, β-, and γ-synucleins, of which only α-synuclein aggregates have been associated with several neurological diseases (Ian et al., Clinical Neurosc. Res. 1:445-455, 2001; Trojanowski and Lee, Neurotoxicology 23:457-460, 2002). The role of synucleins (and in particular, alpha-synuclein) in the etiology of a number of neurodegenerative and/or amyloid diseases has developed from several observations. Pathologically, α-synuclein was identified as a major component of Lewy bodies, the hallmark inclusions of Parkinson's disease, and a fragment thereof was isolated from amyloid plaques of a different neurological disease, Alzheimer's disease. Biochemically, recombinant α-synuclein was shown to form amyloid-like fibrils that recapitulated the ultrastructural features of alpha-synuclein isolated from patients with dementia with Lewy bodies, Parlinson's disease and multiple system atrophy. Additionally, the identification of mutations within the α-synuclein gene, albeit in rare cases of familial Parkinson's disease, demonstrated an unequivocal link between synuclein pathology and neurodegenerative diseases. The common involvement of α-synuclein in a spectrum of diseases such as Parkinson's disease, dementia with Lewy bodies, multiple system atrophy and the Lewy body variant of Alzheimer's disease has led to the classification of these diseases under the umbrella term of “synucleinopathies.”
Fibrillization and aggregation of α-synuclein is thought to play major role in neuronal dysfunction and death of dopaminergic neurons in PD. Mutations in α-synuclein or genomic triplication of wild type α-synuclein (leading to its overexpression) cause certain rare familial forms of Parkinson's disease. In vitro and in vivo models suggest that over-expression of wild-type α-synuclein induces neuronal cell death. See, e.g., Polymeropoulos, et al. (1997) Science 276(5321):2045-7, Kruger, et al. (1998) Nat. Genet. 18(2):106-8, Singleton, et al. (2003) Science 302(5646):841, Miller, et al. (2004) Neurology 62(10):1835-8, Hashimoto, et al. (2003) Ann NY Acad Sci. 991:171-88, Lo Bianco, et al. (2002) Proc Natl Acad Sci USA. 99(16):10813-8, Lee, et al. (2002) Proc Natl Acad Sci USA. 99(13):8968-73, Masliah, et al. (2000) Science 287(5456):1265-9, Auluck, et al. (2002) Science 295(5556):865-8, Oluwatosin-Chigbu et al. (2003) Biochem Biophys Res Commun 309(3): 679-84, Klucken et al. (2004) J Biol. Chem. 279(24):25497-502. Protecting neurons from the toxic effects of α-synuclein is a promising strategy for treating Parkinson's disease and other synucleinopathies such as Lewy body dementia.
Thus, there is a need for compounds and compositions that prevent α-synuclein toxicity and/or aggregation and/or promote α-synuclein fibril disaggregation. Such compounds and composition are useful in treating or ameliorating one or more symptoms of α-synuclein mediated diseases and disorders, or diseases and disorders in which a-synuclein fibril formation is implicated, including but not limited to, Parkinson's disease, dementia with Lewy bodies, multiple system atrophy and the Lewy body variant of Alzheimer's disease.
SUMMARY
Provided herein are compounds, compositions containing the compounds, and methods of use of the compounds as α-synuclein inhibitors. Also provided are methods of treatment or amelioration of one or more symptoms of diseases and disorders associated with α-synuclein toxicity. Also provided are methods of treatment or amelioration of one or more symptoms of diseases and disorders associated with α-synuclein fibril formation. Such diseases and disorders include, but are not limited to, Parkinson's disease and Lewy body dementia. Other diseases and disorders include tauopathies, such as, but not limited to, Alzheimer's disease.
Use of any of the described compounds for the treatment or amelioration of one or more symptoms of diseases and disorders associated with α-synuclein toxicity or α-synuclein fibril formation is also contemplated. Furthermore, use of any of the described compounds for the manufacture of a medicament for the treatment of diseases and disorders associated with α-synuclein toxicity or α-synuclein fibril formation is also contemplated.
In one embodiment, the compounds for use in the compositions and methods provided herein have Formula I:
where X is O, S or NR, where R is hydrogen, alkyl, alkenyl, alkynyl, cycloalkyl, heterocyclyl, aryl, heteroaryl or aralkyl;
Y is NRR′ or OH; where R′ is hydrogen, alkyl, alkenyl, alkynyl, cycloalkyl, heterocyclyl, aryl, heteroaryl or aralkyl;
Z is a direct bond or NR;
R 1 is hydrogen, alkyl, alkenyl, alkynyl, cycloalkyl, heterocyclyl, aryl, heteroaryl, aralkyl, aralkenyl, heteroaralkyl or heteroaralkenyl;
n is 0 to 4;
R 2 is selected from (i) or (ii) as follows:
(i) hydrogen, alkyl, alkenyl, alkynyl, aryl, heteroaryl, heteroarylium, cycloalkyl, heterocyclyl, C(A)R 110 , halo, pseudohalo, OR 111 , S(D) a R 112 , NR 115 R 116 or N + R 115 R 116 R 117 ; or
(ii) any two R 2 groups, which substitute adjacent atoms on the ring, together form alkylene, alkenylene, alkynylene or heteroalkylene;
A is O, S or NR 125 ;
R 110 is hydrogen, alkyl, alkenyl, alkynyl, aryl, heteroaryl, heteroarylium, cycloalkyl, heterocyclyl, C(A)R 126 , halo pseudohalo, OR 125 , SR 125 , NR 127 R 128 and SiR 122 R 123 R 124 ;
R 111 is hydrogen, alkyl, alkenyl, alkynyl, aryl, heteroaryl, heteroarylium, cycloalkyl, heterocyclyl, C(A)R 129 , NR 130 R 131 and SiR 122 R 123 R 124 ;
D is O or NR 125 ;
a is 0, 1 or 2;
when a is 1 or 2, R 112 is selected from hydrogen, alkyl, alkenyl, alkynyl, aryl, heteroaryl, heteroarylium, cycloalkyl, heterocyclyl, halo, pseudohalo, OR 125 , SR 125 and NR 132 R 133 ;
when a is 0, R 112 is selected from hydrogen, alkyl, alkenyl, alkynyl, aryl, heteroaryl, heteroarylium, cycloalkyl, heterocyclyl, SR 125 and C(A)R 129 ;
R 115 , R 116 and R 117 are each independently selected from (a) and (b) as follows:
(a) hydrogen, alkyl, alkenyl, alkynyl, aryl, heteroaryl, heteroarylium, cycloalkyl, heterocyclyl, C(A)R 129 , OR 125 or NR 132 R 133 ; or
(b) any two of R 115 , R 116 and R 117 together form alkylene, alkenylene, alkynylene, heteroalkylene, and the other is selected as in (a);
R 122 , R 123 and R 124 are selected as in (i) or (ii) as follows:
(i) R 122 , R 123 and R 124 are each independently hydrogen, alkyl, alkenyl, alkynyl, aryl, heteroaryl, heteroarylium, cycloalkyl, heterocyclyl, OR 125 or N 132 R 133 ; or
(ii) any two of R 122 , R 123 and R 124 together form alkylene, alkenylene, alkynylene, heteroalkylene; and the other is selected as in (i);
R 125 is hydrogen, alkyl, alkenyl, alkynyl, aryl, heteroaryl, heteroarylium, cycloalkyl or heterocyclyl;
R 126 is hydrogen, alkyl, alkenyl, alkynyl, aryl, heteroaryl, heteroarylium, cycloalkyl, heterocyclyl, OR 125 or N 134 R 135 ; where R 134 and R 135 are each independently hydrogen, alkyl, alkenyl, alkynyl, aryl, heteroaryl, heteroarylium, cycloalkyl, heterocyclyl, OR 136 or NR 132 R 133 , or R 134 and R 135 together form alkylene, alkenylene, alkynylene, heteroalkylene, where R 136 is hydrogen, alkyl, alkenyl, alkynyl, aryl, heteroaryl, heteroarylium, cycloalkyl or heterocyclyl;
R 127 and R 128 are selected as in (i) or (ii) as follows:
(i) R 127 and R 128 are each independently hydrogen, alkyl, alkenyl, alkynyl, aryl, heteroaryl, heteroarylium, cycloalkyl, heterocyclyl, OR 125 , NR 137 R 138 or C(A)R 39 , where R 137 and R 138 are each independently hydrogen, alkyl, alkenyl, alkynyl, aryl, heteroaryl, heteroarylium, cycloalkyl or heterocyclyl, or together form alkylene, alkenylene, alkynylene, heteroalkylene; and R 139 is hydrogen, alkyl, alkenyl, alkynyl, aryl, heteroaryl, heteroarylium, cycloalkyl, heterocyclyl, OR 140 or NR 132 R 133 , where R 140 is alkyl, alkenyl, alkynyl, aryl, heteroaryl, heteroarylium, cycloalkyl, heterocyclyl; or
(ii) R 127 and R 128 together form alkylene, alkenylene, alkynylene, heteroalkylene;
R 129 is hydrogen, alkyl, alkenyl, alkynyl, aryl, heteroaryl, heteroarylium, cycloalkyl, heterocyclyl, OR 140 or NR 132 R 133 ;
R 130 and R 131 are each independently hydrogen, alkyl, alkenyl, alkynyl, aryl, heteroaryl, heteroarylium, cycloalkyl, heterocyclyl or C(A)R 141 , where R 141 is alkyl, alkenyl, alkynyl, aryl, heteroaryl, heteroarylium, cycloalkyl, heterocyclyl, OR 125 or NR 132 R 133 ; or R 130 and R 131 together form alkylene, alkenylene, alkynylene, heteroalkylene;
R 132 and R 133 are each independently hydrogen, alkyl, alkenyl, alkynyl, aryl, heteroaryl, heteroarylium, cycloalkyl, heterocyclyl, or R 132 and R 133 together form alkylene, alkenylene, alkynylene, heteroalkylene; and
R 3 is hydrogen, alkyl, alkenyl, alkynyl, cycloalkyl, heterocyclyl, aryl or heteroaryl;
wherein X, Y, Z, R 1 , R 2 and R 3 are each independently unsubstituted or substituted with one or more substituents, in one embodiment one, two or three substituents, each independently selected from Q 1 , where Q 1 is halo, pseudohalo, hydroxy, oxo, thia, nitrile, nitro, formyl, mercapto, hydroxycarbonyl, hydroxycarbonylalkyl, hydroxycarbonylalkenyl, alkyl, haloalkyl, polyhaloalkyl, aminoalkyl, diaminoalkyl, alkenyl containing 1 to 2 double bonds, alkynyl containing 1 to 2 triple bonds, cycloalkyl, cycloalkylalkyl, heterocyclyl, heterocyclylalkyl, aryl, heteroaryl, aralkyl, aralkenyl, aralkynyl, heteroarylalkyl, trialkylsilyl, dialkylarylsilyl, alkyldiarylsilyl, triarylsilyl, alkylidene, arylalkylidene, alkylcarbonyl, arylcarbonyl, heteroarylcarbonyl, alkoxycarbonyl, alkoxycarbonylalkyl, alkoxyxarbonylalkoxy, aryloxycarbonyl, aryloxycarbonylalkyl, aralkoxycarbonyl, aralkoxycarbonylalkyl, aralkoxycarbonylalkoxy, arylcarbonylalkyl, aminocarbonyl, aminocarbonylalkyl, aminocarbonylalkoxy, alkylaminocarbonyl, alkylaminocarbonylalkyl, alkylaminocarbonylalkoxy, dialkylaminocarbonyl, dialkylaminocarbonylalkyl, dialkylaminocarbonylalkoxy, arylaminocarbonyl, arylaminocarbonylalkyl, arylaminocarbonylalokoxy, diarylaminocarbonyl, diarylaminocarbonylalkyl, diarylaminocarbonyl alkoxy, arylalkylaminocarbonyl, arylalkylaminocarbonylalkyl, arylalkylaminocarbonylalkoxy, alkoxy, aryloxy, heteroaryloxy, heteroaralkoxy, heterocyclyloxy, cycloalkoxy, perfluoroalkoxy, alkenyloxy, alkynyloxy, aralkoxy, alkylcarbonyloxy, arylcarbonyloxy, aralkylcarbonyloxy, alkoxycarbonyloxy, aryloxycarbonyloxy, aralkoxycarbonyloxy, aminocarbonyloxy, alkylaminocarbonyloxy, dialkylaminocarbonyloxy, alkylarylaminocarbonyloxy, diarylaminocarbonyloxy, guanidino, isothioureido, ureido, N-alkylureido, N-arylureido, N′-alkylureido, N′,N′-dialkylureido, N′-alkyl-N′-arylureido, N′,N′-diarylureido, N′-arylureido, N,N′-diarylureido, N-alkyl-N′-arylureido, N-aryl-N′-alkylureido, N,N′-diarylureido, N,N′,N′-trialkylureido, N,N′-dialkyl-N′-arylureido, N-alkyl-N′,N′-diarylureido, N-aryl-N′,N′-dialkylureido, N,N′-diaryl-N′-alkylureido, N,N′,N′-triarylureido, amidino, alkylamidino, arylamidino, aminothiocarbonyl, alkylaminothiocarbonyl, arylaminothiocarbonyl, amino, aminoalkyl, alkylaminoalkyl, dialkylaminoalkyl, arylaminoalkyl, diarylaminoalkyl, alkylarylaminoalkyl, alkylamino, dialkylamino, haloalkylamino, arylamino, diarylamino, alkylarylamino, alkylcarbonylamino, alkoxycarbonylamino, aralkoxycarbonylamino, arylcarbonylamino, arylcarbonylaminoalkyl, aryloxycarbonylaminoalkyl, aryloxyarylcarbonylamino, aryloxycarbonylamino, alkylsulfonylamino, arylsulfonylamino, heteroarylsulfonylamino, heterocyclylsulfonylamino, heteroarylthio, azido, —N + R 151 R 152 R 153 , P(R 150 ) 2 , P(═O)(R 150 ) 2 , OP(═O)(R 150 ) 2 , —NR 160 C(═O)R 163 , dialkylphosphonyl, alkylarylphosphonyl, diarylphosphonyl, hydroxyphosphonyl, alkylthio, arylthio, perfluoroalkylthio, hydroxycarbonylalkylthio, thiocyano, isothiocyano, alkylsulfinyloxy, alkylsulfonyloxy, arylsulfinyloxy, arylsulfonyloxy, hydroxysulfonyloxy, alkoxysulfonyloxy, aminosulfonyloxy, alkylaminosulfonyloxy, dialkylaminosulfonyloxy, arylaminosulfonyloxy, diarylaminosulfonyloxy, alkylarylaminosulfonyloxy, alkylsulfinyl, alkylsulfonyl, arylsulfinyl, arylsulfonyl, hydroxysulfonyl, alkoxysulfonyl, aminosulfonyl, alkylaminosulfonyl, dialkylaminosulfonyl, arylaminosulfonyl, diarylaminosulfonyl or alkylarylaminosulfonyl; azido, tetrazolyl or two Q 1 groups, which substitute atoms in a 1,2 or 1,3 arrangement, together form alkylenedioxy (i.e., —O—(CH 2 ) y —O—), thioalkylenoxy (i.e., —S—(CH 2 ) y —O—) or alkylenedithioxy (i.e., —S—(CH 2 ) y —S—) where y is 1 or 2; or two Q 1 groups, which substitute the same atom, together form alkylene; and
each Q 1 is independently unsubstituted or substituted with one or more substituents, in one embodiment one, two or three substituents, each independently selected from Q 2 ;
each Q 2 is independently halo, pseudohalo, hydroxy, oxo, thia, nitrile, nitro, formyl, mercapto, hydroxycarbonyl, hydroxycarbonylalkyl, hydroxycarbonylalkenyl alkyl, haloalkyl, polyhaloalkyl, aminoalkyl, diaminoalkyl, alkenyl containing 1 to 2 double bonds, alkynyl containing 1 to 2 triple bonds, cycloalkyl, cycloalkylalkyl, heterocyclyl, heterocyclylalkyl, aryl, heteroaryl, aralkyl, aralkenyl, aralkynyl, heteroarylalkyl, trialkylsilyl, dialkylarylsilyl, alkyldiarylsilyl, triarylsilyl, alkylidene, arylalkylidene, alkylcarbonyl, arylcarbonyl, heteroarylcarbonyl, alkoxycarbonyl, alkoxycarbonylalkyl, aryloxycarbonyl, aryloxycarbonylalkyl, aralkoxycarbonyl, aralkoxycarbonylalkyl, arylcarbonylalkyl, aminocarbonyl, alkylaminocarbonyl, dialkylaminocarbonyl, arylaminocarbonyl, diarylaminocarbonyl, arylalkylaminocarbonyl, alkoxy, aryloxy, heteroaryloxy, heteroaralkoxy, heterocyclyloxy, cycloalkoxy, perfluoroalkoxy, alkenyloxy, alkynyloxy, aralkoxy, alkylcarbonyloxy, arylcarbonyloxy, aralkylcarbonyloxy, alkoxycarbonyloxy, aryloxycarbonyloxy, aralkoxycarbonyloxy, aminocarbonyloxy, alkylaminocarbonyloxy, dialkylaminocarbonyloxy, alkylarylaminocarbonyloxy, diarylaminocarbonyloxy, guanidino, isothioureido, ureido, N-alkylureido, N-arylureido, N′-alkylureido, N′,N′-dialkylureido, N′-alkyl-N′-arylureido, N′,N′-diarylureido, N′-arylureido, N,N′-dialkylureido, N-alkyl-N′-arylureido, N-aryl-N′-alkylureido, N,N′-diarylureido, N,N′,N′-trialkylureido, N,N′-dialkyl-N′-arylureido, N-alkyl-N′,N′-diarylureido, N-aryl-N′,N′-dialkylureido, N,N′-diaryl-N′-alkylureido, N,N′,N′-triarylureido, amidino, alkylamidino, arylamidino, aminothiocarbonyl, alkylaminothiocarbonyl, arylaminothiocarbonyl, amino, aminoalkyl, alkylaminoalkyl, dialkylaminoalkyl, arylaminoalkyl, diarylaminoalkyl, alkylarylaminoalkyl, alkylamino, dialkylamino, haloalkylamino, arylamino, diarylamino, alkylarylamino, alkylcarbonylamino, alkoxycarbonylamino, aralkoxycarbonylamino, arylcarbonylamino, arylcarbonylaminoalkyl, aryloxycarbonylaminoalkyl, aryloxyarylcarbonylamino, aryloxycarbonylamino, alkylsulfonylamino, arylsulfonylamino, heteroarylsulfonylamino, heterocyclylsulfonylamino, heteroarylthio, azido, —N + R 151 R 152 R 153 , P(R 150 ) 2 , P(═O)(R 150 ) 2 , OP(═O)(R 150 ) 2 , —NR 160 C(═O)R 163 , dialkylphosphonyl, alkylarylphosphonyl, diarylphosphonyl, hydroxyphosphonyl, alkylthio, arylthio, perfluoroalkylthio, hydroxycarbonylalkylthio, thiocyano, isothiocyano, alkylsulfinyloxy, alkylsulfonyloxy, arylsulfinyloxy, arylsulfonyloxy, hydroxysulfonyloxy, alkoxysulfonyloxy, aminosulfonyloxy, alkylaminosulfonyloxy, dialkylaminosulfonyloxy, arylaminosulfonyloxy, diarylaminosulfonyloxy, alkylarylaminosulfonyloxy, alkylsulfinyl, alkylsulfonyl, arylsulfinyl, arylsulfonyl, hydroxysulfonyl, alkoxysulfonyl, aminosulfonyl, alkylaminosulfonyl, dialkylaminosulfonyl, arylaminosulfonyl, diarylaminosulfonyl or alkylarylaminosulfonyl; or two Q 2 groups, which substitute atoms in a 1,2 or 1,3 arrangement, together form alkylenedioxy (i.e., —O—(CH 2 ) y —O—), thioalkylenoxy (i.e., —S—(CH 2 ) y —O—) or alkylenedithioxy (i.e., —S—(CH 2 ) y —S—) where y is 1 or 2; or two Q 2 groups, which substitute the same atom, together form alkylene;
R 150 is hydroxy, alkoxy, aralkoxy, alkyl, heteroaryl, heterocyclyl, aryl or —NR 170 R 171 , where R 170 and R 171 are each independently hydrogen, alkyl, aralkyl, aryl, heteroaryl, heteroaralkyl or heterocyclyl, or R 170 and R 171 together form alkylene, azaalkylene, oxaalkylene or thiaalkylene;
R 151 , R 152 and R 153 are each independently hydrogen, alkyl, aryl, aralkyl, heteroaryl, heteroaralkyl, heterocyclyl or heterocyclylalkyl;
R 160 is hydrogen, alkyl, aryl, aralkyl, heteroaryl, heteroaralkyl, heterocyclyl or heterocyclylalkyl; and
R 163 is alkoxy, aralkoxy, alkyl, heteroaryl, heterocyclyl, aryl or —NR 170 R 171 .
In one embodiment, R 1 is substituted with one or more substituents independently selected from aryloxy, aryl, heteroaryl, halo, pseudohalo, alkyl, alkoxy, cycloalkyl, alkoxycarbonyl, hydroxycarbonyl, alkylamino, and dialkylamino.
As one of skill in the art will recognize, Formula I structurally sets forth one tautomeric form of the compounds encompassed therein; all such tautomeric forms are contemplated herein.
In another embodiment, the compounds for use in the compositions and methods provided herein have Formula II:
where X 1 is O, S and NR;
Ar is aryl or heteroaryl;
R 4 is hydrogen, alkyl, alkenyl, alkynyl, cycloalkyl, heterocyclyl, aryl or heteroaryl;
R 5 is selected as for R 2 ;
m is 0 to 4; and
R 6 is hydrogen, alkyl, alkenyl, alkynyl, cycloalkyl, heterocyclyl, aryl or heteroaryl;
where X 1 , Ar, R 4 , R 5 and R 6 are each independently unsubstituted or substituted with one or more, in one embodiment one, two or three substituents, each independently selected from Q 1 .
In another embodiment, the compounds for use in the compositions and methods provided herein have Formula III:
where Ar 1 is aryl, heteroaryl, or cycloalkyl;
R 7 is hydrogen, alkyl, alkenyl, alkynyl, cycloalkyl, heterocyclyl, aryl, heteroaryl or NRR, where R is hydrogen or alkyl;
R 8 and R 9 are each independently selected as for R 2 ; and
R 10 is hydrogen, alkyl, alkenyl, alkynyl, cycloalkyl, heterocyclyl, aryl or heteroaryl;
where Ar 1 , R 7 , R 8 , R 9 and R 10 are each independently unsubstituted or substituted with one or more, in one embodiment one, two or three substituents, each independently selected from Q 1 .
In some embodiments, Ar 1 is aryl, heteroaryl or cycloalkyl, and is unsubstituted or substituted with alkyl, alkenyl, alkynyl, aryl, heteroaryl, halo, pseudohalo, dialkylamino, aryloxy, aralkoxy, haloalkyl, alkoxy, haloalkoxy, cycloalkyl, heteroaryl, or COOR, where R is hydrogen or alkyl.
In some embodiments, R 8 and R 9 are each independently selected from (i) and (ii) as follows:
(i) R 8 and R 9 together with the atoms to which they are attached form a fused phenyl ring; and
(ii) R 8 is CN or COOR 200 , where R 200 is hydrogen, alkyl, alkenyl, alkynyl, cycloalkyl, heterocyclyl, aryl or heteroaryl; and R 9 is hydrogen, alkyl or alkylthio; and
R 10 is hydrogen.
In one embodiment of (i) above, R 8 and R 9 together with the atoms to which they are attached form a fused phenyl ring, which is unsubstituted or substituted with halo, pseudohalo, alkyl, alkoxy, cycloalkyl, fused cycloalkyl, fused heterocyclyl, fused heteroaryl, aryl (e.g., phenyl), and fused aryl (e.g., fused phenyl ring), which is unsubstituted or substituted with halo, pseudohalo, alkyl, alkoxy, aryl, cycloalkyl, heterocyclyl, fused aryl, fused heterocyclyl, and fused cycloalkyl.
In another embodiment, Ar 1 is phenyl, naphthyl, pyridyl, furyl, or thienyl, and is unsubstituted or substituted with alkyl, alkenyl, halo, pseudohalo, dialkylamino, aryloxy, haloalkyl, alkoxy, aryloxy, cycloalkyl, heterocyclyl, fused heterocyclyl, aryl, fused aryl, heteroaryl, fused heteroaryl, or COOR, where R is hydrogen or alkyl.
In another embodiment, the compounds for use in the compositions and methods provided herein have Formula IV:
where Ar 2 is aryl or heteroaryl; and
R 11 , R 12 , R 13 , R 14 , R 15 , R 16 and R 17 are each independently selected as for R 2 ;
where Ar 2 , R 11 , R 12 , R 13 , R 14 , R 15 , R 16 and R 17 are each independently unsubstituted or substituted with one or more substituents, in one embodiment one, two or three substituents, each independently selected from Q 1 .
In another embodiment, the compounds for use in the compositions and methods provided herein have Formula V:
where X 2 is N or CR;
Ar 3 is aryl, alkyl, cycloalkyl, heterocyclyl, heteroaryl, alkenyl, alkynyl or COO-alkyl;
R 18 , R 20 and R 21 are each independently selected as for R 2 ;
q is 0 to 4; and
R 19 and R 20 are each independently hydrogen, alkyl, alkenyl, alkynyl, cycloalkyl, heterocyclyl, aryl or heteroaryl;
where X 2 , Ar 2 , R 18 , R 20 , R 21 , R 19 and R 22 are each independently unsubstituted or substituted with one or more substituents, in one embodiment one, two or three substituents, each independently selected from Q 1 .
In another embodiment, the compounds for use in the compositions and methods provided herein have Formula VI:
where X, R 2 , R 3 and n are as defined elsewhere herein;
R 25 and R 26 , together with the atoms to which they are attached, form a heterocyclyl or heteroaryl ring;
b is 1 when the N—R 26 bond is a single bond;
b is 0 when the N—R 26 bond is a double bond; and
R 27 is hydrogen, alkyl, alkenyl, alkynyl, cycloalkyl, heterocyclyl, aryl or heteroaryl
where X, R 2 , R 3 , R 25 , R 26 and R 27 are each independently unsubstituted or substituted with one or more substituents, in one embodiment one, two or three substituents, each independently selected from Q 1 .
In another embodiment, the compounds for use in the compositions and methods provided herein have Formula VII:
where X is O, S or NR, where R is hydrogen or alkyl;
Y is NRR or OH;
Z is a direct bond or NR;
R 1 is alkyl, alkenyl, alkynyl, cycloalkyl, aryl, heteroaryl, aralkyl, or aralkenyl;
R 2 is halo, pseudohalo, alkyl, cycloalkyl, alkoxy, aryl, aralkoxy, heteroaryl, aralkyl, or heteroaralkyl;
n is 0, 1, or 2;
R 3 is hydrogen or alkyl; and
where X, Y, Z, R 1 , R 2 and R 3 are each independently unsubstituted or substituted with one or more substituents, in one embodiment one, two or three substituents, each independently selected from Q 1 . As one of skill in the art will recognize, Formula VII structurally sets forth one tautomeric form of the genus of compounds; all such tautomeric forms are contemplated herein.
Also provided are pharmaceutically-acceptable derivatives, including salts, esters, enol ethers, enol esters, solvates, hydrates and prodrugs of the compounds described herein. Pharmaceutically-acceptable salts, include, but are not limited to, amine salts, such as but not limited to N,N′-dibenzylethylenediamine, chloroprocaine, choline, ammonia, diethanolamine and other hydroxyalkylamines, ethylenediamine, N-methylglucamine, procaine, N-benzylphenethylamine, 1-para-chlorobenzyl-2-pyrrolidin-1′-ylmethylbenzimidazole, diethylamine and other alkylamines, piperazine and tris(hydroxymethyl)aminomethane; alkali metal salts, such as but not limited to lithium, potassium and sodium; alkali earth metal salts, such as but not limited to barium, calcium and magnesium; transition metal salts, such as but not limited to zinc, aluminum, and other metal salts, such as but not limited to sodium hydrogen phosphate and disodium phosphate; and also including, but not limited to, salts of mineral acids, such as but not limited to hydrochlorides and sulfates; and salts of organic acids, such as but not limited to acetates, lactates, malates, tartrates, citrates, ascorbates, succinates, butyrates, valerates and fumarates.
Further provided are pharmaceutical compositions containing the compounds provided herein and a pharmaceutically acceptable carrier. In one embodiment, the pharmaceutical compositions are formulated for single dosage administration.
Also provided are methods of treating or ameliorating one or more symptoms of α-synuclein-mediated diseases or disorders. Such diseases and disorders include, but are not limited to, Parkinson's disease, dementia with Lewy bodies, multiple system atrophy and the Lewy body variant of Alzheimer's disease.
Method of treating or ameliorating one or more symptoms associated with α-synuclein toxicity are provided. Methods of prevention of α-synuclein fibril formation are provided. Methods of disruption or disaggregation of α-synuclein fibrils are provided. In further embodiments, methods of restoring vesicle trafficking and/or reversing changes in lipid metabolism are provided. In another embodiment, methods of slowing or reversing or ameliorating neurodegeneration are provided.
In practicing the methods, effective amounts of the compounds or compositions containing therapeutically effective concentrations of the compounds are administered.
Articles of manufacture are provided containing packaging material, a compound or composition provided herein which is useful for treating or ameliorating one or more symptoms of α-synuclein-mediated diseases or disorders, and a label that indicates that the compound or composition is useful for treating or ameliorating one or more symptoms of α-synuclein-mediated diseases or disorders.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 sets forth the structures for certain compounds according to Formula I, as described herein.
FIG. 2 sets forth the structures for certain compounds according to Formula VII, as described herein.
FIG. 3 sets forth the structures for certain compounds according to Formula III, as described herein.
DETAILED DESCRIPTION
A. Definitions
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as is commonly understood by one of ordinary skill in the art to which this invention belongs. All patents, applications, published applications and other publications are incorporated by reference in their entirety. In the event that there are a plurality of definitions for a term herein, those in this section prevail unless stated otherwise.
As used herein, α-synuclein refers to one in a family of structurally related proteins that are prominently expressed in the central nervous system. Aggregated α-synuclein proteins form brain lesions that are hallmarks of some neurodegenerative diseases (synucleinopathies). The gene for α-synuclein, which is called SNCA, is on chromosome 4q21. One form of hereditary Parkinson disease is due to mutations in SNCA. Another form of hereditary Parkinson disease is due to a triplication of SNCA.
As used herein, pharmaceutically acceptable derivatives of a compound include salts, esters, enol ethers, enol esters, acetals, ketals, orthoesters, hemiacetals, hemiketals, acids, bases, solvates, hydrates or prodrugs thereof. Such derivatives may be readily prepared by those of skill in this art using known methods for such derivatization. The compounds produced may be administered to animals or humans without substantial toxic effects and either are pharmaceutically active or are prodrugs. Pharmaceutically acceptable salts include, but are not limited to, amine salts, such as but not limited to N,N′-dibenzylethylenediamine, chloroprocaine, choline, ammonia, diethanolamine and other hydroxyalkylamines, ethylenediamine, N-methylglucamine, procaine, N-benzylphenethylamine, 1-para-chlorobenzyl-2-pyrrolidin-1′-ylmethyl-benzimidazole, diethylamine and other alkylamines, piperazine and tris(hydroxymethyl)aminomethane; alkali metal salts, such as but not limited to lithium, potassium and sodium; alkali earth metal salts, such as but not limited to barium, calcium and magnesium; transition metal salts, such as but not limited to zinc; and other metal salts, such as but not limited to sodium hydrogen phosphate and disodium phosphate; and also including, but not limited to, nitrates, borates, methanesulfonates, benzenesulfonates, toluenesulfonates, salts of mineral acids, such as but not limited to hydrochlorides, hydrobromides, hydroiodides and sulfates; and salts of organic acids, such as but not limited to acetates, trifluoroacetates, maleates, oxalates, lactates, malates, tartrates, citrates, benzoates, salicylates, ascorbates, succinates, butyrates, valerates and fumarates. Pharmaceutically acceptable esters include, but are not limited to, alkyl, alkenyl, alkynyl, aryl, heteroaryl, aralkyl, heteroaralkyl, cycloalkyl and heterocyclyl esters of acidic groups, including, but not limited to, carboxylic acids, phosphoric acids, phosphinic acids, sulfonic acids, sulfinic acids and boronic acids. Pharmaceutically acceptable enol ethers include, but are not limited to, derivatives of formula C═C(OR) where R is hydrogen, alkyl, alkenyl, alkynyl, aryl, heteroaryl, aralkyl, heteroaralkyl, cycloalkyl or heterocyclyl. Pharmaceutically acceptable enol esters include, but are not limited to, derivatives of formula C═C(OC(O)R) where R is hydrogen, alkyl, alkenyl, alkynyl, aryl, heteroaryl, aralkyl, heteroaralkyl, cycloalkyl or heterocyclyl. Pharmaceutically acceptable solvates and hydrates are complexes of a compound with one or more solvent or water molecules, or 1 to about 100, or 1 to about 10, or one to about 2, 3 or 4, solvent or water molecules.
As used herein, treatment means any manner in which one or more of the symptoms of a disease or disorder are ameliorated or otherwise beneficially altered. Treatment also encompasses any pharmaceutical use of the compositions herein, such as use for treating diseases or disorders in which α-synuclein fibril formation is implicated.
As used herein, amelioration of the symptoms of a particular disorder by administration of a particular compound or pharmaceutical composition refers to any lessening, whether permanent or temporary, lasting or transient that can be attributed to or associated with administration of the composition.
As used herein, IC 50 refers to an amount, concentration or dosage of a particular test compound that achieves a 50% inhibition of a maximal response, such as modulation of α-synuclein fibril formation, in an assay that measures such response.
As used herein, EC 50 refers to a dosage, concentration or amount of a particular test compound that elicits a dose-dependent response at 50% of maximal expression of a particular response that is induced, provoked or potentiated by the particular test compound.
As used herein, a prodrug is a compound that, upon in vivo administration, is metabolized by one or more steps or processes or otherwise converted to the biologically, pharmaceutically or therapeutically active form of the compound. To produce a prodrug, the pharmaceutically active compound is modified such that the active compound will be regenerated by metabolic processes. The prodrug may be designed to alter the metabolic stability or the transport characteristics of a drug, to mask side effects or toxicity, to improve the flavor of a drug or to alter other characteristics or properties of a drug. By virtue of knowledge of pharmacodynamic processes and drug metabolism in vivo, those of skill in this art, once a pharmaceutically active compound is known, can design prodrugs of the compound (see, e.g., Nogrady (1985) Medicinal Chemistry A Biochemical Approach, Oxford University Press, New York, pages 388-392).
It is to be understood that the compounds provided herein may contain chiral centers. Such chiral centers may be of either the (R) or (S) configuration, or may be a mixture thereof. Thus, the compounds provided herein may be enantiomerically pure, or be stereoisomeric or diastereomeric mixtures. In the case of amino acid residues, such residues may be of either the L- or D-form. The configuration for naturally occurring amino acid residues is generally L. When not specified the residue is the L form. As used herein, the term “amino acid” refers to α-amino acids which are racemic, or of either the D- or L-configuration. The designation “d” preceding an amino acid designation (e.g., dAla, dSer, dVal, etc.) refers to the D-isomer of the amino acid. The designation “dl” preceding an amino acid designation (e.g., dlPip) refers to a mixture of the L- and D-isomers of the amino acid. It is to be understood that the chiral centers of the compounds provided herein may undergo epimerization in vivo. As such, one of skill in the art will recognize that administration of a compound in its (R) form is equivalent, for compounds that undergo epimerization in vivo, to administration of the compound in its (S) form.
As used herein, substantially pure means sufficiently homogeneous to appear free of readily detectable impurities as determined by standard methods of analysis, such as thin layer chromatography (TLC), gel electrophoresis, high performance liquid chromatography (HPLC) and mass spectrometry (MS), used by those of skill in the art to assess such purity, or sufficiently pure such that further purification would not detectably alter the physical and chemical properties, such as enzymatic and biological activities, of the substance. Methods for purification of the compounds to produce substantially chemically pure compounds are known to those of skill in the art. A substantially chemically pure compound may, however, be a mixture of stereoisomers. In such instances, further purification might increase the specific activity of the compound.
As used herein, “alkyl,” “alkenyl” and “alkynyl” carbon chains, if not specified, contain from 1 to 20 carbons, or 1 or 2 to 16 carbons, and are straight or branched. Alkenyl carbon chains of from 2 to 20 carbons, in certain embodiments, contain 1 to 8 double bonds and alkenyl carbon chains of 2 to 16 carbons, in certain embodiments, contain 1 to 5 double bonds. Alkynyl carbon chains of from 2 to 20 carbons, in certain embodiments, contain 1 to 8 triple bonds, and the alkynyl carbon chains of 2 to 16 carbons, in certain embodiments, contain 1 to 5 triple bonds. Exemplary alkyl, alkenyl and alkynyl groups herein include, but are not limited to, methyl, ethyl, propyl, isopropyl, isobutyl, n-butyl, sec-butyl, tert-butyl, isopentyl, neopentyl, tert-pentyl, isohexyl, alkyl (propenyl) and propargyl (propynyl). As used herein, lower alkyl, lower alkenyl, and lower alkynyl refer to carbon chains having from about 1 or about 2 carbons up to about 6 carbons. As used herein, “alk(en)(yn)yl” refers to an alkyl group containing at least one double bond and at least one triple bond.
As used herein, “cycloalkyl” refers to a saturated mono- or multi-cyclic ring system, in certain embodiments of 3 to 10 carbon atoms, in other embodiments of 3 to 6 carbon atoms; cycloalkenyl and cycloalkynyl refer to mono- or multicyclic ring systems that respectively include at least one double bond and at least one triple bond. Cycloalkenyl and cycloalkynyl groups may, in certain embodiments, contain 3 to 10 carbon atoms, with cycloalkenyl groups, in further embodiments, containing 4 to 7 carbon atoms and cycloalkynyl groups, in further embodiments, containing 8 to 10 carbon atoms. The ring systems of the cycloalkyl, cycloalkenyl and cycloalkynyl groups may be composed of one ring or two or more rings which may be joined together in a fused, bridged or spiro-connected fashion. “Cycloalk(en)(yn)yl” refers to a cycloalkyl group containing at least one double bond and at least one triple bond.
As used herein, “aryl” refers to aromatic monocyclic or multicyclic groups containing from 6 to 19 carbon atoms. Aryl groups include, but are not limited to groups such as unsubstituted or substituted fluorenyl, unsubstituted or substituted phenyl, and unsubstituted or substituted naphthyl.
As used herein, “heteroaryl” refers to a monocyclic or multicyclic aromatic ring system, in certain embodiments, of about 5 to about 15 members where one or more, in one embodiment 1 to 3, of the atoms in the ring system is a heteroatom, that is, an element other than carbon, including but not limited to, nitrogen, oxygen or sulfur. The heteroaryl group may be optionally fused to a benzene ring. Heteroaryl groups include, but are not limited to, furyl, imidazolyl, pyrimidinyl, tetrazolyl, thienyl, pyridyl, pyrrolyl, thiazolyl, isothiazolyl, oxazolyl, isoxazolyl, triazolyl, quinolinyl and isoquinolinyl.
As used herein, a “heteroarylium” group is a heteroaryl group that is positively charged on one or more of the heteroatoms.
As used herein, “heterocyclyl” refers to a monocyclic or multicyclic non-aromatic ring system, in one embodiment of 3 to 10 members, in another embodiment of 4 to 7 members, in a further embodiment of 5 to 6 members, where one or more, in certain embodiments, 1 to 3, of the atoms in the ring system is a heteroatom, that is, an element other than carbon, including but not limited to, nitrogen, oxygen or sulfur. In embodiments where the heteroatom(s) is(are) nitrogen, the nitrogen is optionally substituted with alkyl, alkenyl, alkynyl, aryl, heteroaryl, aralkyl, heteroaralkyl, cycloalkyl, heterocyclyl, cycloalkylalkyl, heterocyclylalkyl, acyl, guanidino, or the nitrogen may be quaternized to form an ammonium group where the substituents are selected as above.
As used herein, “aralkyl” refers to an alkyl group in which one of the hydrogen atoms of the alkyl is replaced by an aryl group.
As used herein, “heteroaralkyl” refers to an alkyl group in which one of the hydrogen atoms of the alkyl is replaced by a heteroaryl group.
As used herein, “halo”, “halogen” or “halide” refers to F, Cl, Br or I.
As used herein, pseudohalides or pseudohalo groups are groups that behave substantially similar to halides. Such compounds can be used in the same manner and treated in the same manner as halides. Pseudohalides include, but are not limited to, cyanide, cyanate, thiocyanate, selenocyanate, trifluoromethoxy, and azide.
As used herein, “haloalkyl” refers to an alkyl group in which one or more of the hydrogen atoms are replaced by halogen. Such groups include, but are not limited to, chloromethyl, trifluoromethyl and 1-chloro-2-fluoroethyl.
As used herein, “haloalkoxy” refers to RO— in which R is a haloalkyl group.
As used herein, “sulfinyl” or “thionyl” refers to —S(O)—. As used herein, “sulfonyl” or “sulfuryl” refers to —S(O) 2 —. As used herein, “sulfo” refers to —S(O) 2 O—.
As used herein, “carboxy” refers to a divalent radical, —C(O)O—.
As used herein, “aminocarbonyl” refers to —C(O)NH 2 .
As used herein, “alkylaminocarbonyl” refers to —C(O)NHR in which R is alkyl, including lower alkyl. As used herein, “dialkylaminocarbonyl” refers to —C(O)NR′R in which R′ and R are independently alkyl, including lower alkyl; “carboxamide” refers to groups of formula —NR′COR in which R′ and R are independently alkyl, including lower alkyl.
As used herein, “diarylaminocarbonyl” refers to —C(O)NRR′ in which R and R′ are independently selected from aryl, including lower aryl, such as phenyl.
As used herein, “arylalkylaminocarbonyl” refers to —C(O)NRR′ in which one of R and R′ is aryl, including lower aryl, such as phenyl, and the other of R and R′ is alkyl, including lower alkyl.
As used herein, “arylaminocarbonyl” refers to —C(O)NHR in which R is aryl, including lower aryl, such as phenyl.
As used herein, “hydroxycarbonyl” refers to —COOH.
As used herein, “alkoxycarbonyl” refers to —C(O)OR in which R is alkyl, including lower alkyl.
As used herein, “aryloxycarbonyl” refers to —C(O)OR in which R is aryl, including lower aryl, such as phenyl.
As used herein, “alkoxy” and “alkylthio” refer to RO— and RS—, in which R is alkyl, including lower alkyl.
As used herein, “aryloxy” and “arylthio” refer to RO— and RS—, in which R is aryl, including lower aryl, such as phenyl.
As used herein, “alkylene” refers to a straight, branched or cyclic, in certain embodiments straight or branched, divalent aliphatic hydrocarbon group, in one embodiment having from 1 to about 20 carbon atoms, in another embodiment having from 1 to 12 carbons. In a further embodiment alkylene includes lower alkylene. There may be optionally inserted along the alkylene group one or more oxygen, sulfur, including S(═O) and S(═O) 2 groups, or substituted or unsubstituted nitrogen atoms, including —NR— and —N + RR— groups, where the nitrogen substituent(s) is(are) alkyl, aryl, aralkyl, heteroaryl, heteroaralkyl or COR′, where R′ is alkyl, aryl, aralkyl, heteroaryl, heteroaralkyl, —OY or —NYY, where Y is hydrogen, alkyl, aryl, heteroaryl, cycloalkyl or heterocyclyl. Alkylene groups include, but are not limited to, methylene (—CH 2 —), ethylene (—CH 2 CH 2 —), propylene (—(CH 2 ) 3 —), methylenedioxy (—O—CH 2 —O—) and ethylenedioxy (—O—(CH 2 ) 2 —O—). The term “lower alkylene” refers to alkylene groups having 1 to 6 carbons. In certain embodiments, alkylene groups are lower alkylene, including alkylene of 1 to 3 carbon atoms.
As used herein, “azaalkylene” refers to —(CRR) n —NR—(CRR) m —, where n and m are each independently an integer from 0 to 4. As used herein, “oxaalkylene” refers to —(CRR) n —O—(CRR) m —, where n and m are each independently an integer from 0 to 4. As used herein, “thiaalkylene” refers to —(CRR) n —S—(CRR) m —, —(CRR) n —S(═O)—(CRR) m —, and —(CRR) n —S(═O) 2 —(CRR) m , where n and m are each independently an integer from 0 to 4.
As used herein, “alkenylene” refers to a straight, branched or cyclic, in one embodiment straight or branched, divalent aliphatic hydrocarbon group, in certain embodiments having from 2 to about 20 carbon atoms and at least one double bond, in other embodiments 1 to 12 carbons. In further embodiments, alkenylene groups include lower alkenylene. There may be optionally inserted along the alkenylene group one or more oxygen, sulfur or substituted or unsubstituted nitrogen atoms, where the nitrogen substituent is alkyl. Alkenylene groups include, but are not limited to, —CH═CH—CH═CH— and —CH═CH—CH 2 —. The term “lower alkenylene” refers to alkenylene groups having 2 to 6 carbons. In certain embodiments, alkenylene groups are lower alkenylene, including alkenylene of 3 to 4 carbon atoms.
As used herein, “alkynylene” refers to a straight, branched or cyclic, in certain embodiments straight or branched, divalent aliphatic hydrocarbon group, in one embodiment having from 2 to about 20 carbon atoms and at least one triple bond, in another embodiment 1 to 12 carbons. In a further embodiment, alkynylene includes lower alkynylene. There may be optionally inserted along the alkynylene group one or more oxygen, sulfur or substituted or unsubstituted nitrogen atoms, where the nitrogen substituent is alkyl. Alkynylene groups include, but are not limited to, —C≡C—C≡C—, —C≡C— and —C≡C—CH 2 —. The term “lower alkynylene” refers to alkynylene groups having 2 to 6 carbons. In certain embodiments, alkynylene groups are lower alkynylene, including alkynylene of 3 to 4 carbon atoms.
As used herein, “alk(en)(yn)ylene” refers to a straight, branched or cyclic, in certain embodiments straight or branched, divalent aliphatic hydrocarbon group, in one embodiment having from 2 to about 20 carbon atoms and at least one triple bond, and at least one double bond; in another embodiment 1 to 12 carbons. In further embodiments, alk(en)(yn)ylene includes lower alk(en)(yn)ylene. There may be optionally inserted along the alkynylene group one or more oxygen, sulfur or substituted or unsubstituted nitrogen atoms, where the nitrogen substituent is alkyl. Alk(en)(yn)ylene groups include, but are not limited to, —C═C—(CH 2 ) n —C≡C—, where n is 1 or 2. The term “lower alk(en)(yn)ylene” refers to alk(en)(yn)ylene groups having up to 6 carbons. In certain embodiments, alk(en)(yn)ylene groups have about 4 carbon atoms.
As used herein, “cycloalkylene” refers to a divalent saturated mono- or multicyclic ring system, in certain embodiments of 3 to 10 carbon atoms, in other embodiments 3 to 6 carbon atoms; cycloalkenylene and cycloalkynylene refer to divalent mono- or multicyclic ring systems that respectively include at least one double bond and at least one triple bond. Cycloalkenylene and cycloalkynylene groups may, in certain embodiments, contain 3 to 10 carbon atoms, with cycloalkenylene groups in certain embodiments containing 4 to 7 carbon atoms and cycloalkynylene groups in certain embodiments containing 8 to 10 carbon atoms. The ring systems of the cycloalkylene, cycloalkenylene and cycloalkynylene groups may be composed of one ring or two or more rings which may be joined together in a fused, bridged or spiro-connected fashion. “Cycloalk(en)(yn)ylene” refers to a cycloalkylene group containing at least one double bond and at least one triple bond.
As used herein, “arylene” refers to a monocyclic or polycyclic, in certain embodiments monocyclic, divalent aromatic group, in one embodiment having from 5 to about 20 carbon atoms and at least one aromatic ring, in another embodiment 5 to 12 carbons. In further embodiments, arylene includes lower arylene. Arylene groups include, but are not limited to, 1,2-, 1,3- and 1,4-phenylene. The term “lower arylene” refers to arylene groups having 6 carbons.
As used herein, “heteroarylene” refers to a divalent monocyclic or multicyclic aromatic ring system, in one embodiment of about 5 to about 15 atoms in the ring(s), where one or more, in certain embodiments 1 to 3, of the atoms in the ring system is a heteroatom, that is, an element other than carbon, including but not limited to, nitrogen, oxygen or sulfur. The term “lower heteroarylene” refers to heteroarylene groups having 5 or 6 atoms in the ring.
As used herein, “heterocyclylene” refers to a divalent monocyclic or multicyclic non-aromatic ring system, in certain embodiments of 3 to 10 members, in one embodiment 4 to 7 members, in another embodiment 5 to 6 members, where one or more, including 1 to 3, of the atoms in the ring system is a heteroatom, that is, an element other than carbon, including but not limited to, nitrogen, oxygen or sulfur.
As used herein, “substituted alkyl,” “substituted alkenyl,” “substituted alkynyl,” “substituted cycloalkyl,” “substituted cycloalkenyl,” “substituted cycloalkynyl,” “substituted aryl,” “substituted heteroaryl,” “substituted heterocyclyl,” “substituted alkylene,” “substituted alkenylene,” “substituted alkynylene,” “substituted cycloalkylene,” “substituted cycloalkenylene,” “substituted cycloalkynylene,” “substituted arylene,” “substituted heteroarylene” and “substituted heterocyclylene” refer to alkyl, alkenyl, alkynyl, cycloalkyl, cycloalkenyl, cycloalkynyl, aryl, heteroaryl, heterocyclyl, alkylene, alkenylene, alkynylene, cycloalkylene, cycloalkenylene, cycloalkynylene, arylene, heteroarylene and heterocyclylene groups, respectively, that are substituted with one or more substituents, in certain embodiments one, two, three or four substituents, where the substituents are as defined herein, in one embodiment selected from Q 1 .
As used herein, “alkylidene” refers to a divalent group, such as ═CR′R″, which is attached to one atom of another group, forming a double bond. Alkylidene groups include, but are not limited to, methylidene (═CH 2 ) and ethylidene (═CHCH 3 ). As used herein, “arylalkylidene” refers to an alkylidene group in which either R′ or R″ is an aryl group. “Cycloalkylidene” groups are those where R′ and R″ are linked to form a carbocyclic ring. “Heterocyclylid-ene” groups are those where at least one of R′ and R″ contain a heteroatom in the chain, and R′ and R″ are linked to form a heterocyclic ring.
As used herein, “amido” refers to the divalent group —C(O)NH—. “Thioamido” refers to the divalent group —C(S)NH—. “Oxyamido” refers to the divalent group —OC(O)NH—. “Thiaamido” refers to the divalent group —SC(O)NH—. “Dithiaamido” refers to the divalent group —SC(S)NH—. “Ureido” refers to the divalent group —HNC(O)NH—. “Thioureido” refers to the divalent group —HNC(S)NH—.
As used herein, “semicarbazide” refers to —NHC(O)NHNH—. “Carbazate” refers to the divalent group —OC(O)NHNH—. “Isothiocarbazate” refers to the divalent group —SC(O)NHNH—. “Thiocarbazate” refers to the divalent group —OC(S)NHNH—. “Sulfonylhydrazide” refers to the divalent group —SO 2 NHNH—. “Hydrazide” refers to the divalent group —C(O)NHNH—. “Azo” refers to the divalent group —N═N—. “Hydrazinyl” refers to the divalent group —NH—NH—.
Where the number of any given substituent is not specified (e.g., haloalkyl), there may be one or more substituents present. For example, “haloalkyl” may include one or more of the same or different halogens.
As used herein, the abbreviations for any protective groups, amino acids and other compounds, are, unless indicated otherwise, in accord with their common usage, recognized abbreviations, or the IUPAC-IUB Commission on Biochemical Nomenclature (see, (1972) Biochem. 11:942-944).
B. Compounds
The compounds provided herein for use in the compositions and methods provided herein exhibit in vitro and in vivo activity against α-synuclein mediated diseases and disorders. In one embodiment, the compounds treat or ameliorate one or more symptoms associated with α-synuclein toxicity. In one embodiment, the compounds affect aggregation of α-synuclein or fragments thereof. In another embodiment, the compounds do not affect aggregation, but still exert a therapeutic affect on α-synuclein toxicity.
In one embodiment, the compounds for use in the compositions and methods provided herein have Formula I:
where X is O, S or NR, where R is hydrogen or alkyl;
Y is NRR′ or OH, where R′ is hydrogen or alkyl;
Z is a direct bond or NR;
R 1 is alkyl, alkenyl, alkynyl, cycloalkyl, aryl, heterocyclyl, heteroaryl, aralkyl, aralkenyl, heteroaralkyl, or heteroaralkenyl;
R 2 is halo, pseudohalo, alkoxy or alkyl;
n is 0 or 1;
R 3 is hydrogen or alkyl;
wherein X, Y, Z, R 1 , R 2 and R 3 are each independently unsubstituted or substituted with one or more substituents, in one embodiment one, two or three substituents, each independently selected from Q 1 .
In one embodiment, R 1 is substituted with one or more substituents independently selected from aryloxy, aryl, heteroaryl, halo, pseudohalo, alkyl, alkoxy, cycloalkyl, alkoxycarbonyl, hydroxycarbonyl, alkylamino, and dialkylamino.
In another embodiment, the compounds have Formula I where R is hydrogen.
In another embodiment, the compounds have Formula I where n is 0 or 1.
In another embodiment, the compounds have Formula I where X is S, O or NH.
In another embodiment, the compounds have Formula I where Y is NH 2 .
In another embodiment, the compounds have Formula I where Z is a direct bond or NH.
In another embodiment, the compounds have Formula I where R is ethyl, 2-(2-furyl)ethenyl, phenyl, methyl, 2-naphthyloxymethyl, benzyl, 3-chloro-2-benzothienyl, cyclopropyl, cyclopropylmethyl, isobutyl, 4-tert-butylphenyl, 4-biphenyl, tert-butyl, 3-chlorophenyl, 2-furyl, 2,4-dichlorophenyl, 3,4-dimethoxyphenyl, 2-(4-methoxyphenyl)ethenyl, 4-methoxyphenoxymethyl, isopentyl, isopropyl, 2-cyclopentylethyl, cyclopentylmethyl, 2-phenylpropyl, 2-phenylethyl, 1-methyl-2-phenylethyl, 1-methyl-2-phenylethenyl, 2-benzylethyl, 2-phenylethenyl, 5-hexynyl, 3-butynyl, 4-pentynyl, propyl, butyl, pentyl, hexyl, t-butoxymethyl, t-butylmethyl, 1-ethylpentyl, cyclopentyl, cyclohexyl, cyclobutyl, 2-cyclopentylethyl, cyclopentylmethyl, 2-fluorocyclopropyl, 2-methylcyclopropyl, 2-phenylcyclopropyl, 2,2-dimethylethenyl, 1,2-propenyl, 2-(3-trifluoromethylphenyl)ethenyl, 3,4-butenyl, 2-(2-furyl)ethyl, 2-chloroethenyl, 2-(2-chlorophenyl)ethenyl, 1-methyl-2,2-dichlorocyclopropyl, 2,2-difluorocyclopropyl, methylpropionate, proprionic acid, methylbutyrate, butyric acid, pentanoic acid, methyl-t-butylether, dimethylaminomethyl, 2-(2-tetrahydrofuryl)-ethyl, or 2-(2-tetrahydrofuryl)-methyl.
In another embodiment, R 2 is halo or alkyl. In another embodiment, R 2 is chloro or methyl.
In another embodiment, R 3 is hydrogen.
In another embodiment, compounds of Formula I include:
In another embodiment, the compounds of Formula I can have a structure as set forth in FIG. 1 .
In another embodiment, the compounds for use in the compositions and methods provided herein have Formula II:
where X 1 is O or NR, where R is H or alkyl;
Ar is aryl or heteroaryl, and is unsubstituted or substituted with alkoxy, alkyl, hydroxy, alkylenedioxy, dialkylamino, heterocyclyl or carboxy;
R 4 is alkyl or hydrogen;
R 5 is halo or pseudohalo;
m is 0 or 1;
R 6 is hydrogen or alkyl;
wherein X 1 , Ar, R 4 , R 5 and R 6 are each independently unsubstituted or substituted with one or more substituents, in one embodiment one, two or three substituents, each independently selected from Q 1 .
In another embodiment, the compounds have Formula II where X 1 is O or NH.
In another embodiment, the compounds have Formula II where Ar is phenyl, naphthyl, indolyl, pyridyl, thienyl or furyl, and is unsubstituted or substituted with alkoxy, alkyl, hydroxy, alkylenedioxy, dialkylamino, heterocyclyl or carboxy. In another embodiment, the compounds have Formula II where Ar is phenyl, naphthyl, indolyl, pyridyl, thienyl or furyl, and is unsubstituted or substituted with methoxy, tert-butyl, hydroxy, methylenedioxy, methyl, dimethylamino, morpholinyl or carboxy. In another embodiment, the compounds have Formula II where Ar is 4,8-dimethoxy-1-naphthyl, 3-indolyl, phenyl, 3-pyridyl, 3,5-di-tert-butyl-4-hydroxyphenyl, 2,3-dimethoxyphenyl, 3,4-methylenedioxyphenyl, 2-thienyl, 3,4-dimethoxyphenyl, 5-methyl-2-furyl, 4-dimethylaminophenyl, 4-(4-morpholinyl)phenyl, 3-methoxyphenyl, 2-naphthyl, 2-pyridyl, 5-(4-carboxyphenyl)-2-furyl or 4-methoxyphenyl.
In another embodiment, the compounds have Formula II where R 4 is H.
In another embodiment, the compounds have Formula II where R 5 is Cl.
In another embodiment, the compounds have Formula II where m is 0 or 1.
In another embodiment, the compounds have Formula II where R 6 is H, In another embodiment, compounds of Formula II include:
In another embodiment, the compounds for use in the compositions and methods provided herein have Formula III:
where Ar 1 is aryl or heteroaryl, and is unsubstituted or substituted with alkyl, alkenyl, halo, pseudohalo, dialkylamino, aryloxy, haloalkyl, alkoxy, cycloalkyl, heteroaryl, or COOR, where R is hydrogen or alkyl;
R 7 is hydrogen or NRR, where R is hydrogen or alkyl;
R 8 and R 9 are each independently selected from (i) and (ii) as follows:
(i) R 8 and R 9 together with the atoms to which they are attached form a fused phenyl ring; and
(ii) R 8 is CN or COOR 200 , where R 200 is hydrogen, alkyl, alkenyl, alkynyl, cycloalkyl, heterocyclyl, aryl or heteroaryl; and R 9 is hydrogen, alkyl or alkylthio; and
R 10 is hydrogen;
where Ar 1 , R 7 , R 8 , R 9 and R 10 are each independently unsubstituted or substituted with one or more, in one embodiment one, two or three substituents, each independently selected from Q 1 .
In one embodiment of (i) above, R 8 and R 9 together with the atoms to which they are attached form a fused phenyl ring, which is unsubstituted or substituted with halo, pseudohalo, alkyl, alkoxy, cycloalkyl, fused cycloalkyl, fused heterocyclic, fused heteroaryl, aryl (e.g., phenyl), and fused aryl (e.g., fused phenyl ring), which is unsubstituted or substituted with halo, pseudohalo, alkyl, alkoxy, aryl, cycloalkyl, heterocyclyl, fused aryl, fused heterocyclyl, and fused cycloalkyl.
In another embodiment, Ar 1 is phenyl, naphthyl, pyridyl, furyl, or thienyl, and is unsubstituted or substituted with alkyl, alkenyl, halo, pseudohalo, dialkylamino, aryloxy, haloalkyl, alkoxy, aryloxy, cycloalkyl, heterocyclyl, fused heterocyclyl, aryl, fused aryl, heteroaryl, fused heteroaryl, or COOR, where R is hydrogen or alkyl.
In another embodiment, Ar 1 is substituted with methyl, fluoro, bromo, chloro, iodo, dimethylamino, phenoxy, trifluoromethyl or methoxycarbonyl.
In another embodiment, Ar 1 is phenyl, 2-thienyl, 3-thienyl, 2-furyl, 3-furyl, 5-chloro-2-thienyl, 5-bromo-2-thienyl, 3-methyl-2-thienyl, 5-methyl-2-thienyl, 5-ethyl-2-thienyl, 2-methylphenyl, 3-methylphenyl, 3-trifluoromethyl, 3-bromophenyl, 4-fluoro-3-bromophenyl, 2-fluorophenyl, 3,4-difluorophenyl, 2-chlorophenyl, 3-chlorophenyl, 3,4-dichlorophenyl, 3,4,5,-methoxyphenyl, 2,4-methoxyphenyl, 2-fluoro-5-bromophenyl, 4-dimethylaminophenyl, 2-trifluoromethyl-4-fluorophenyl, 3-trifluoromethyl-4-fluorophenyl, 2-fluoro-3-chlorophenyl, 3-bromo-4-fluorophenyl, perfluorophenyl, 3-pyridyl, 4-pyridyl, 4-bromophenyl, 4-chlorophenyl, 3-phenoxyphenyl, 2,4-dichlorophenyl, 2,3-difluorophenyl, 2-chlorophenyl, 2-fluoro-6-chlorophenyl, 1-naphthyl, 4-trifluoromethylphenyl, 2-trifluoromethylphenyl, 4-trifluoromethoxyphenyl, or 4-methoxycarbonylphenyl.
In another embodiment, R 7 is hydrogen or dialkylamino. In another embodiment, R 7 is hydrogen or diethylamino.
In another embodiment, R 8 and R 9 are each independently selected from (i) and (ii) as follows:
(i) R 8 and R 9 together with the atoms to which they are attached form a fused phenyl ring, which is unsubstituted or substituted with methyl, chloro, methoxy or another fused phenyl ring, which is unsubstituted or substituted with bromo; and
(ii) R 8 is CN or COOR 200 , where R 200 is methyl, benzyl, ethyl, 4-methoxybenzyl or 2-phenylethyl; and R 9 is methyl, methylthio or phenylaminocarbonylmethylthio.
In another embodiment, compounds of Formula III include:
In another embodiment, compounds according to Formula III can have a structure as set forth in FIG. 3 .
In another embodiment, the compounds for use in the compositions and methods provided herein have Formula IV:
where Ar 2 is heteroaryl; and
R 11 , R 12 , R 13 , R 14 and R 15 are each independently hydrogen, halo, pseudohalo, nitro, alkoxy, dialkylamino or aralkoxy; and
R 16 and R 17 are each hydrogen;
In another embodiment, the compounds have Formula IV where Ar 2 is thienyl. In another embodiment, the compounds have Formula IV where Ar 2 is 2-thienyl.
In another embodiment, the compounds have Formula IV where R 11 , R 12 , R 13 , R 14 and R 15 are each independently hydrogen, chloro, nitro, methoxy, dimethylamino, benzyloxy, ethoxy or cyano.
In another embodiment, the compounds of Formula IV are:
In another embodiment, the compounds for use in the compositions and methods provided herein have Formula V:
where X 2 is N;
Ar 3 is aryl, alkyl, cycloalkyl, heteroaryl or COO-alkyl, and is optionally substituted with halo, pseudohalo, alkyl or alkoxy;
q is 0;
R 20 is alkyl;
R 21 and R 22 are hydrogen; and
R 19 is hydrogen, alkyl or aralkyl, optionally substituted with halo or pseudohalo.
In another embodiment, the compounds have Formula V wherein Ar 3 is phenyl, methyl, thienyl, cyclopropyl or COOEt, and is optionally substituted with fluoro, chloro, tert-butyl or methoxy. In another embodiment, the compounds have Formula V wherein Ar 3 is 4-fluorophenyl, methyl, 2-thienyl, cyclopropyl, COOEt, 4-chlorophenyl, 4-tert-butylphenyl or 4-methoxyphenyl.
In another embodiment, the compounds have Formula V wherein R 20 is methyl.
In another embodiment, the compounds have Formula V wherein R 19 is hydrogen, methyl or 2-fluorobenzyl.
In another embodiment, the compounds of Formula V are:
In another embodiment, the compounds for use in the compositions and methods provided herein have Formula VI:
where X is O or S;
R 2 is alkyl;
n is 0 or 1;
R 3 is hydrogen;
R 25 and R 26 , together with the atoms to which they are attached, form a heterocyclyl or heteroaryl ring;
b is 1 when the N—R 26 bond is a single bond;
b is 0 when the N—R 26 bond is a double bond; and
R 27 is hydrogen or alkyl;
where X, R 2 , R 3 , R 25 , R 26 and R 27 are each independently unsubstituted or substituted with one or more substituents, in one embodiment one, two or three substituents, each independently selected from Q 1 .
In another embodiment, the compounds have Formula VI where R 2 is methyl.
In another embodiment, the compounds have Formula VI where R 25 and R 26 , together with the atoms to which they are attached, form a imidazolidinone, pyrimidine, pyrimidinone or triazine ring system, optionally fused to an aryl or cycloalkyl ring, and optionally substituted with alkyl, alkoxycarbonylalkylidene, hydroxycarbonylalkyl, alkoxyalkyl, aralkyl, carboxy, alkoxycarbonylalkyl, arylaminocarbonyl or heterocyclylalkyl. In another embodiment, the compounds have Formula VI where R 25 and R 26 , together with the atoms to which they are attached, form one of the following ring systems:
In another embodiment, the compounds have Formula VI where R 27 is hydrogen or methyl.
In another embodiment, the compounds of Formula VI are:
In another aspect, compounds according to Formula VII:
are provided for use in the compositions and methods described herein,
where X is O, S or NR,
where R is hydrogen or alkyl;
Y is NRR or OH;
Z is a direct bond or NR;
R 1 is allyl, alkenyl, alkynyl, cycloalkyl, aryl, heteroaryl, aralkyl, or aralkenyl;
R 2 is halo, pseudohalo, alkyl, cycloalkyl, alkoxy, aryl, aralkoxy, heteroaryl, aralkyl, or heteroaralkyl;
n is 0, 1, or 2;
R 3 is hydrogen or alkyl; and
where X, Y, Z, R 1 , R 2 and R 3 are each independently unsubstituted or substituted with one or more substituents, in one embodiment one, two or three substituents, each independently selected from Q 1 .
In one embodiment, Z is a direct bond.
In another embodiment, Y is NH 2 .
In one embodiment, R 3 is H.
In one embodiment, R 1 is substituted with one or more substituents independently selected from aryloxy, aryl, heteroaryl, halo, pseudohalo, alkyl, alkoxy, cycloalkyl, alkoxycarbonyl, and hydroxycarbonyl.
In another embodiment, the compounds have Formula VII where R is hydrogen.
In another embodiment, the compounds have Formula VII where n is 0 or 1.
In another embodiment, the compounds have Formula VII where X is S, O or NH.
In another embodiment, the compounds have Formula VII where Z is a direct bond or NH.
In another embodiment, when n=2 and the R 2 groups substitute adjacent carbon atoms, the R 2 groups can form a fused cycloalkyl group (e.g., cyclopentyl, cyclohexyl group) together with the C atoms they substitute.
In another embodiment, the compounds have Formula VII where R 1 is ethyl, cyclopropyl or 2-(2-furyl)-ethenyl.
In another embodiment, R 2 is phenyl.
In another embodiment, when n=2 and the R 2 groups substitute adjacent carbon atoms, the R 2 groups are both phenyl.
Particular compounds according to Formula VII are also set forth in FIG. 2 .
C. Preparation of the Compounds
The compounds for use in the compositions and methods provided herein may be obtained from commercial sources (e.g., Aldrich Chemical Co., Milwaukee, Wis.), may be prepared by methods well known to those of skill in the art, or may be prepared by the methods shown herein. One of skill in the art would be able to prepare all of the compounds for use herein by routine modification of these methods using the appropriate starting materials.
Certain of the compounds provided herein may be made by the synthetic route shown below. Briefly, aryl amines or heteroaryl amines are converted to 1 using the corresponding nitrile. Compound 1 can also be synthesized in other ways including from aryl halides or heteroaryl halides using the corresponding guanidinium salt. Compound 1 is treated with acyl halides or anhydrides to make the corresponding acylated compound 2, which can be converted to the corresponding amide 3 by reaction with ammonia. Compound 1 is converted to a five membered heterocyclic compound 4 by reagent 10 and a suitable base such as pyridine or dimethyl amino pyridine in dichloromethane. Compound 1 is converted to a six membered heterocyclic compound 5 by reagent 11 or reagent 12 and a suitable base. Compound 1 is converted to six membered heterocyclic compound 6 by reagent 13 and a base. Compound 1 is converted to six membered heterocyclic compound 7 by reagent 14 with a suitable base and solvent.
Aryl amine or a heteroaryl amine is converted to compound 8 by reagent 14 with a suitable base and solvent. Compound 8 can be further treated with ammonia to make the corresponding imine, which is acylated to yield compound 9.
Other compounds provided herein can be prepared by the scheme shown below. Briefly, heteroaryl 15 is treated with hydrazine and base in a suitable solvent to synthesize hydrazine derivative 16. 16 is converted to imine 17 by treatment with carbonyl compound 18.
Other compounds provided herein may be prepared using the general schemes set forth in the Examples, below. For example, Methods 1-4 as shown in Example 2 can be used to prepare various examples of compound 1, which can be converted to certain compounds provided herein (e.g., according to Formula I) using the methods set forth in Method L. Similarly, Methods 5 and 6 as shown in Example 2 can be used to prepare compounds according to Formula VII.
Further compounds provided herein may be prepared by the scheme shown below. Briefly, amine 19 is acylated by treatment with acetic anhydride and base. This acyl intermediate product is then treated with a suitable aldehyde and Lewis or protic acid to synthesize lactam 20. The nitrogen of the lactam 20 can be protected and the carbon adjacent to the carbonyl functionalized by standard substitution reactions.
Other compounds provided herein may be synthesized according to the following scheme. Briefly, aldehyde 21 and methyl acetate undergo a condensation reaction to yield an unsaturated ester, which is hydrolyzed to the corresponding acid by a suitable base. The acid can then be converted directly to unsaturated carbonyl 23 by treatment with protic acid. The acid can also be converted to the corresponding acid chloride 22 by treatment with thionyl chloride, the acid chloride 22 can then undergo a Friedel Crafts acylation with 24 to form an unsaturated carbonyl 23.
Further compounds provided herein may be synthesized according to the scheme shown below. Briefly, hydrazine 24 is converted to amine 25 by treating it with amide 28 and base. The amine 25 can be acylated with 29 to yield 26. Hydrazine 24 is converted to pyrrole 27 by treatment with a dicarbonyl compound 30.
D. Formulation of Pharmaceutical Compositions
The pharmaceutical compositions provided herein contain therapeutically effective amounts of one or more of the compounds provided herein that are useful in the treatment or amelioration of one or more of the symptoms of diseases or disorders associated with α-synuclein toxicity, α-synuclein fibril formation, or in which α-synuclein fibril formation is implicated, and a pharmaceutically acceptable carrier. Diseases or disorders associated with α-synuclein toxicity and/or α-synuclein fibril formation include, but are not limited to, Parkinson's disease and Lewy body dementia. Pharmaceutical carriers suitable for administration of the compounds provided herein include any such carriers known to those skilled in the art to be suitable for the particular mode of administration.
In addition, the compounds may be formulated as the sole pharmaceutically active ingredient in the composition or may be combined with other active ingredients.
The compositions contain one or more compounds provided herein. The compounds are, in one embodiment, formulated into suitable pharmaceutical preparations such as solutions, suspensions, tablets, dispersible tablets, pills, capsules, powders, sustained release formulations or elixirs, for oral administration or in sterile solutions or suspensions for parenteral administration, as well as transdermal patch preparation and dry powder inhalers. In one embodiment, the compounds described above are formulated into pharmaceutical compositions using techniques and procedures well known in the art (see, e.g., Ansel Introduction to Pharmaceutical Dosage Forms, Fourth Edition 1985, 126).
In the compositions, effective concentrations of one or more compounds or pharmaceutically acceptable derivatives thereof is (are) mixed with a suitable pharmaceutical carrier. The compounds may be derivatized as the corresponding salts, esters, enol ethers or esters, acetals, ketals, orthoesters, hemiacetals, hemiketals, acids, bases, solvates, hydrates or prodrugs prior to formulation, as described above. The concentrations of the compounds in the compositions are effective for delivery of an amount, upon administration, that treats or ameliorates one or more of the symptoms of diseases or disorders associated with α-synuclein toxicity, α-synuclein fibril formation or in which α-synuclein toxicity and/or fibril formation is implicated.
In one embodiment, the compositions are formulated for single dosage administration. To formulate a composition, the weight fraction of compound is dissolved, suspended, dispersed or otherwise mixed in a selected carrier at an effective concentration such that the treated condition is relieved or one or more symptoms are ameliorated.
The active compound is included in the pharmaceutically acceptable carrier in an amount sufficient to exert a therapeutically useful effect in the absence of undesirable side effects on the patient treated. The therapeutically effective concentration may be determined empirically by testing the compounds in in vitro and in vivo systems described herein (see, e.g., EXAMPLE 1) and in U.S. patent application Ser. No. 10/826,157, filed Apr. 16, 2004, and U.S. Patent Application Publication No. 2003/0073610, and then extrapolated therefrom for dosages for humans.
The concentration of active compound in the pharmaceutical composition will depend on absorption, inactivation and excretion rates of the active compound, the physicochemical characteristics of the compound, the dosage schedule, and amount administered as well as other factors known to those of skill in the art. For example, the amount that is delivered is sufficient to ameliorate one or more of the symptoms of diseases or disorders associated with α-synuclein fibril formation or in which α-synuclein fibril formation is implicated, as described herein.
In one embodiment, a therapeutically effective dosage should produce a serum concentration of active ingredient of from about 0.1 ng/ml to about 50-100 μg/ml. The pharmaceutical compositions, in another embodiment, should provide a dosage of from about 0.001 mg to about 2000 mg of compound per kilogram of body weight per day. Pharmaceutical dosage unit forms are prepared to provide from about 0.01 mg, 0.1 mg or 1 mg to about 500 mg, 1000 mg or 2000 mg, and in one embodiment from about 10 mg to about 500 mg of the active ingredient or a combination of essential ingredients per dosage unit form.
The active ingredient may be administered at once, or may be divided into a number of smaller doses to be administered at intervals of time. It is understood that the precise dosage and duration of treatment is a function of the disease being treated and may be determined empirically using known testing protocols or by extrapolation from in vivo or in vitro test data. It is to be noted that concentrations and dosage values may also vary with the severity of the condition to be alleviated. It is to be further understood that for any particular subject, specific dosage regimens should be adjusted over time according to the individual need and the professional judgment of the person administering or supervising the administration of the compositions, and that the concentration ranges set forth herein are exemplary only and are not intended to limit the scope or practice of the claimed compositions.
In instances in which the compounds exhibit insufficient solubility, methods for solubilizing compounds may be used. Such methods are known to those of skill in this art, and include, but are not limited to, using cosolvents, such as dimethylsulfoxide (DMSO), using surfactants, such as TWEEN®, or dissolution in aqueous sodium bicarbonate. Derivatives of the compounds, such as prodrugs of the compounds may also be used in formulating effective pharmaceutical compositions.
Upon mixing or addition of the compound(s), the resulting mixture may be a solution, suspension, emulsion or the like. The form of the resulting mixture depends upon a number of factors, including the intended mode of administration and the solubility of the compound in the selected carrier or vehicle. The effective concentration is sufficient for ameliorating the symptoms of the disease, disorder or condition treated and may be empirically determined.
The pharmaceutical compositions are provided for administration to humans and animals in unit dosage forms, such as tablets, capsules, pills, powders, granules, sterile parenteral solutions or suspensions, and oral solutions or suspensions, and oil-water emulsions containing suitable quantities of the compounds or pharmaceutically acceptable derivatives thereof. The pharmaceutically therapeutically active compounds and derivatives thereof are, in one embodiment, formulated and administered in unit-dosage forms or multiple-dosage forms. Unit-dose forms as used herein refers to physically discrete units suitable for human and animal subjects and packaged individually as is known in the art. Each unit-dose contains a predetermined quantity of the therapeutically active compound sufficient to produce the desired therapeutic effect, in association with the required pharmaceutical carrier, vehicle or diluent. Examples of unit-dose forms include ampoules and syringes and individually packaged tablets or capsules. Unit-dose forms may be administered in fractions or multiples thereof. A multiple-dose form is a plurality of identical unit-dosage forms packaged in a single container to be administered in segregated unit-dose form. Examples of multiple-dose forms include vials, bottles of tablets or capsules or bottles of pints or gallons. Hence, multiple dose form is a multiple of unit-doses which are not segregated in packaging.
Liquid pharmaceutically administrable compositions can, for example, be prepared by dissolving, dispersing, or otherwise mixing an active compound as defined above and optional pharmaceutical adjuvants in a carrier, such as, for example, water, saline, aqueous dextrose, glycerol, glycols, ethanol, and the like, to thereby form a solution or suspension. If desired, the pharmaceutical composition to be administered may also contain minor amounts of nontoxic auxiliary substances such as wetting agents, emulsifying agents, solubilizing agents, pH buffering agents and the like, for example, acetate, sodium citrate, cyclodextrine derivatives, sorbitan monolaurate, triethanolamine sodium acetate, triethanolamine oleate, and other such agents.
Actual methods of preparing such dosage forms are known, or will be apparent, to those skilled in this art; for example, see Remington's Pharmaceutical Sciences, Mack Publishing Company, Easton, Pa., 15th Edition, 1975.
Dosage forms or compositions containing active ingredient in the range of 0.005% to 100% with the balance made up from non-toxic carrier may be prepared. Methods for preparation of these compositions are known to those skilled in the art. The contemplated compositions may contain 0.001%-100% active ingredient, in one embodiment 0.1-95%, in another embodiment 75-85%.
1. Compositions for Oral Administration
Oral pharmaceutical dosage forms are either solid, gel or liquid. The solid dosage forms are tablets, capsules, granules, and bulk powders. Types of oral tablets include compressed, chewable lozenges and tablets which may be enteric-coated, sugar-coated or film-coated. Capsules may be hard or soft gelatin capsules, while granules and powders may be provided in non-effervescent or effervescent from with the combination of other ingredients known to those skilled in the art.
a. Solid Compositions for Oral Administration
In certain embodiments, the formulations are solid dosage forms, in one embodiment, capsules or tablets. The tablets, pills, capsules, troches and the like can contain one or more of the following ingredients, or compounds of a similar nature: a binder; a lubricant; a diluent; a glidant; a disintegrating agent; a coloring agent; a sweetening agent; a flavoring agent; a wetting agent; an emetic coating; and a film coating. Examples of binders include microcrystalline cellulose, gum tragacanth, glucose solution, acacia mucilage, gelatin solution, molasses, polyinylpyrrolidine, povidone, crospovidones, sucrose and starch paste. Lubricants include talc, starch, magnesium or calcium stearate, lycopodium and stearic acid. Diluents include, for example, lactose, sucrose, starch, kaolin, salt, mannitol and dicalcium phosphate. Glidants include, but are not limited to, colloidal silicon dioxide. Disintegrating agents include crosscarmellose sodium, sodium starch glycolate, alginic acid, corn starch, potato starch, bentonite, methylcellulose, agar and carboxymethylcellulose. Coloring agents include, for example, any of the approved certified water soluble FD and C dyes, mixtures thereof; and water insoluble FD and C dyes suspended on alumina hydrate. Sweetening agents include sucrose, lactose, mannitol and artificial sweetening agents such as saccharin, and any number of spray dried flavors. Flavoring agents include natural flavors extracted from plants such as fruits and synthetic blends of compounds which produce a pleasant sensation, such as, but not limited to peppermint and methyl salicylate. Wetting agents include propylene glycol monostearate, sorbitan monooleate, diethylene glycol monolaurate and polyoxyethylene laural ether. Emetic-coatings include fatty acids, fats, waxes, shellac, ammoniated shellac and cellulose acetate phthalates. Film coatings include hydroxyethylcellulose, sodium carboxymethylcellulose, polyethylene glycol 4000 and cellulose acetate phthalate.
The compound, or pharmaceutically acceptable derivative thereof, could be provided in a composition that protects it from the acidic environment of the stomach. For example, the composition can be formulated in an enteric coating that maintains its integrity in the stomach and releases the active compound in the intestine. The composition may also be formulated in combination with an antacid or other such ingredient.
When the dosage unit form is a capsule, it can contain, in addition to material of the above type, a liquid carrier such as a fatty oil. In addition, dosage unit forms can contain various other materials which modify the physical form of the dosage unit, for example, coatings of sugar and other enteric agents. The compounds can also be administered as a component of an elixir, suspension, syrup, wafer, sprinkle, chewing gum or the like. A syrup may contain, in addition to the active compounds, sucrose as a sweetening agent and certain preservatives, dyes and colorings and flavors.
The active materials can also be mixed with other active materials which do not impair the desired action, or with materials that supplement the desired action, such as antacids, H2 blockers, and diuretics. The active ingredient is a compound or pharmaceutically acceptable derivative thereof as described herein. Higher concentrations, up to about 98% by weight of the active ingredient may be included.
In all embodiments, tablets and capsules formulations may be coated as known by those of skill in the art in order to modify or sustain dissolution of the active ingredient. Thus, for example, they may be coated with a conventional enterically digestible coating, such as phenylsalicylate, waxes and cellulose acetate phthalate.
b. Liquid Compositions for Oral Administration
Liquid oral dosage forms include aqueous solutions, emulsions, suspensions, solutions and/or suspensions reconstituted from non-effervescent granules and effervescent preparations reconstituted from effervescent granules. Aqueous solutions include, for example, elixirs and syrups. Emulsions are either oil-in-water or water-in-oil.
Elixirs are clear, sweetened, hydroalcoholic preparations. Pharmaceutically acceptable carriers used in elixirs include solvents. Syrups are concentrated aqueous solutions of a sugar, for example, sucrose, and may contain a preservative. An emulsion is a two-phase system in which one liquid is dispersed in the form of small globules throughout another liquid. Pharmaceutically acceptable carriers used in emulsions are non-aqueous liquids, emulsifying agents and preservatives. Suspensions use pharmaceutically acceptable suspending agents and preservatives. Pharmaceutically acceptable substances used in non-effervescent granules, to be reconstituted into a liquid oral dosage form, include diluents, sweeteners and wetting agents. Pharmaceutically acceptable substances used in effervescent granules, to be reconstituted into a liquid oral dosage form, include organic acids and a source of carbon dioxide. Coloring and flavoring agents are used in all of the above dosage forms.
Solvents include glycerin, sorbitol, ethyl alcohol and syrup. Examples of preservatives include glycerin, methyl and propylparaben, benzoic acid, sodium benzoate and alcohol. Examples of non-aqueous liquids utilized in emulsions include mineral oil and cottonseed oil. Examples of emulsifying agents include gelatin, acacia, tragacanth, bentonite, and surfactants such as polyoxyethylene sorbitan monooleate. Suspending agents include sodium carboxymethylcellulose, pectin, tragacanth, Veegum and acacia. Sweetening agents include sucrose, syrups, glycerin and artificial sweetening agents such as saccharin. Wetting agents include propylene glycol monostearate, sorbitan monooleate, diethylene glycol monolaurate and polyoxyethylene lauryl ether. Organic acids include citric and tartaric acid. Sources of carbon dioxide include sodium bicarbonate and sodium carbonate. Coloring agents include any of the approved certified water soluble FD and C dyes, and mixtures thereof. Flavoring agents include natural flavors extracted from plants such fruits, and synthetic blends of compounds which produce a pleasant taste sensation.
For a solid dosage form, the solution or suspension, in for example propylene carbonate, vegetable oils or triglycerides, is in one embodiment encapsulated in a gelatin capsule. Such solutions, and the preparation and encapsulation thereof, are disclosed in U.S. Pat. Nos. 4,328,245; 4,409,239; and 4,410,545. For a liquid dosage form, the solution, e.g., for example, in a polyethylene glycol, may be diluted with a sufficient quantity of a pharmaceutically acceptable liquid carrier, e.g., water, to be easily measured for administration.
Alternatively, liquid or semi-solid oral formulations may be prepared by dissolving or dispersing the active compound or salt in vegetable oils, glycols, triglycerides, propylene glycol esters (e.g., propylene carbonate) and other such carriers, and encapsulating these solutions or suspensions in hard or soft gelatin capsule shells. Other useful formulations include those set forth in U.S. Pat. Nos. RE28,819 and 4,358,603. Briefly, such formulations include, but are not limited to, those containing a compound provided herein, a dialkylated mono- or poly-alkylene glycol, including, but not limited to, 1,2-dimethoxymethane, diglyme, triglyme, tetraglyme, polyethylene glycol-350-dimethyl ether, polyethylene glycol-550-dimethyl ether, polyethylene glycol-750-dimethyl ether wherein 350, 550 and 750 refer to the approximate average molecular weight of the polyethylene glycol, and one or more antioxidants, such as butylated hydroxytoluene (BHT), butylated hydroxyanisole (BHA), propyl gallate, vitamin E, hydroquinone, hydroxycoumarins, ethanolamine, lecithin, cephalin, ascorbic acid, malic acid, sorbitol, phosphoric acid, thiodipropionic acid and its esters, and dithiocarbamates.
Other formulations include, but are not limited to, aqueous alcoholic solutions including a pharmaceutically acceptable acetal. Alcohols used in these formulations are any pharmaceutically acceptable water-miscible solvents having one or more hydroxyl groups, including, but not limited to, propylene glycol and ethanol. Acetals include, but are not limited to, di(lower alkyl)acetals of lower alkyl aldehydes such as acetaldehyde diethyl acetal.
2. Injectables, Solutions and Emulsions
Parenteral administration, in one embodiment characterized by injection, either subcutaneously, intramuscularly or intravenously is also contemplated herein. Injectables can be prepared in conventional forms, either as liquid solutions or suspensions, solid forms suitable for solution or suspension in liquid prior to injection, or as emulsions. The injectables, solutions and emulsions also contain one or more excipients. Suitable excipients are, for example, water, saline, dextrose, glycerol or ethanol. In addition, if desired, the pharmaceutical compositions to be administered may also contain minor amounts of non-toxic auxiliary substances such as wetting or emulsifying agents, pH buffering agents, stabilizers, solubility enhancers, and other such agents, such as for example, sodium acetate, sorbitan monolaurate, triethanolamine oleate and cyclodextrins.
Implantation of a slow-release or sustained-release system, such that a constant level of dosage is maintained (see, e.g., U.S. Pat. No. 3,710,795) is also contemplated herein. Briefly, a compound provided herein is dispersed in a solid inner matrix, e.g., polymethylmethacrylate, polybutylmethacrylate, plasticized or unplasticized polyvinylchloride, plasticized nylon, plasticized polyethyleneterephthalate, natural rubber, polyisoprene, polyisobutylene, polybutadiene, polyethylene, ethylene-vinylacetate copolymers, silicone rubbers, polydimethylsiloxanes, silicone carbonate copolymers, hydrophilic polymers such as hydrogels of esters of acrylic and methacrylic acid, collagen, cross-linked polyvinylalcohol and cross-linked partially hydrolyzed polyvinyl acetate, that is surrounded by an outer polymeric membrane, e.g., polyethylene, polypropylene, ethylene/propylene copolymers, ethylene/ethyl acrylate copolymers, ethylene/vinylacetate copolymers, silicone rubbers, polydimethyl siloxanes, neoprene rubber, chlorinated polyethylene, polyvinylchloride, vinylchloride copolymers with vinyl acetate, vinylidene chloride, ethylene and propylene, ionomer polyethylene terephthalate, butyl rubber epichlorohydrin rubbers, ethylene/vinyl alcohol copolymer, ethylene/vinyl acetate/vinyl alcohol terpolymer, and ethylene/vinyloxyethanol copolymer, that is insoluble in body fluids. The compound diffuses through the outer polymeric membrane in a release rate controlling step. The percentage of active compound contained in such parenteral compositions is highly dependent on the specific nature thereof, as well as the activity of the compound and the needs of the subject.
Parenteral administration of the compositions includes intravenous, subcutaneous and intramuscular administrations. Preparations for parenteral administration include sterile solutions ready for injection, sterile dry soluble products, such as lyophilized powders, ready to be combined with a solvent just prior to use, including hypodermic tablets, sterile suspensions ready for injection, sterile dry insoluble products ready to be combined with a vehicle just prior to use and sterile emulsions. The solutions may be either aqueous or nonaqueous.
If administered intravenously, suitable carriers include physiological saline or phosphate buffered saline (PBS), and solutions containing thickening and solubilizing agents, such as glucose, polyethylene glycol, and polypropylene glycol and mixtures thereof.
Pharmaceutically acceptable carriers used in parenteral preparations include aqueous vehicles, nonaqueous vehicles, antimicrobial agents, isotonic agents, buffers, antioxidants, local anesthetics, suspending and dispersing agents, emulsifying agents, sequestering or chelating agents and other pharmaceutically acceptable substances.
Examples of aqueous vehicles include Sodium Chloride Injection, Ringers Injection, Isotonic Dextrose Injection, Sterile Water Injection, Dextrose and Lactated Ringers Injection. Nonaqueous parenteral vehicles include fixed oils of vegetable origin, cottonseed oil, corn oil, sesame oil and peanut oil. Antimicrobial agents in bacteriostatic or fungistatic concentrations must be added to parenteral preparations packaged in multiple-dose containers which include phenols or cresols, mercurials, benzyl alcohol, chlorobutanol, methyl and propyl p-hydroxybenzoic acid esters, thimerosal, benzalkonium chloride and benzethonium chloride. Isotonic agents include sodium chloride and dextrose. Buffers include phosphate and citrate. Antioxidants include sodium bisulfate. Local anesthetics include procaine hydrochloride. Suspending and dispersing agents include sodium carboxymethylcellulose, hydroxypropyl methylcellulose and polyvinylpyrrolidone. Emulsifying agents include Polysorbate 80 (TWEEN® 80). A sequestering or chelating agent of metal ions include EDTA. Pharmaceutical carriers also include ethyl alcohol, polyethylene glycol and propylene glycol for water miscible vehicles; and sodium hydroxide, hydrochloric acid, citric acid or lactic acid for pH adjustment.
The concentration of the pharmaceutically active compound is adjusted so that an injection provides an effective amount to produce the desired pharmacological effect. The exact dose depends on the age, weight and condition of the patient or animal as is known in the art.
The unit-dose parenteral preparations are packaged in an ampoule, a vial or a syringe with a needle. All preparations for parenteral administration must be sterile, as is known and practiced in the art.
Illustratively, intravenous or intraarterial infusion of a sterile aqueous solution containing an active compound is an effective mode of administration. Another embodiment is a sterile aqueous or oily solution or suspension containing an active material injected as necessary to produce the desired pharmacological effect.
Injectables are designed for local and systemic administration. In one embodiment, a therapeutically effective dosage is formulated to contain a concentration of at least about 0.1% w/w up to about 90% w/w or more, in certain embodiments more than 1% w/w of the active compound to the treated tissue(s).
The compound may be suspended in micronized or other suitable form or may be derivatized to produce a more soluble active product or to produce a prodrug. The form of the resulting mixture depends upon a number of factors, including the intended mode of administration and the solubility of the compound in the selected carrier or vehicle. The effective concentration is sufficient for ameliorating the symptoms of the condition and may be empirically determined.
3. Lyophilized Powders
Of interest herein are also lyophilized powders, which can be reconstituted for administration as solutions, emulsions and other mixtures. They may also be reconstituted and formulated as solids or gels.
The sterile, lyophilized powder is prepared by dissolving a compound provided herein, or a pharmaceutically acceptable derivative thereof, in a suitable solvent. The solvent may contain an excipient which improves the stability or other pharmacological component of the powder or reconstituted solution, prepared from the powder. Excipients that may be used include, but are not limited to, dextrose, sorbital, fructose, corn syrup, xylitol, glycerin, glucose, sucrose or other suitable agent. The solvent may also contain a buffer, such as citrate, sodium or potassium phosphate or other such buffer known to those of skill in the art at, in one embodiment, about neutral pH. Subsequent sterile filtration of the solution followed by lyophilization under standard conditions known to those of skill in the art provides the desired formulation. In one embodiment, the resulting solution will be apportioned into vials for lyophilization. Each vial will contain a single dosage or multiple dosages of the compound. The lyophilized powder can be stored under appropriate conditions, such as at about 4° C. to room temperature.
Reconstitution of this lyophilized powder with water for injection provides a formulation for use in parenteral administration. For reconstitution, the lyophilized powder is added to sterile water or other suitable carrier. The precise amount depends upon the selected compound. Such amount can be empirically determined.
4. Topical Administration
Topical mixtures are prepared as described for the local and systemic administration. The resulting mixture may be a solution, suspension, emulsions or the like and are formulated as creams, gels, ointments, emulsions, solutions, elixirs, lotions, suspensions, tinctures, pastes, foams, aerosols, irrigations, sprays, suppositories, bandages, dermal patches or any other formulations suitable for topical administration.
The compounds or pharmaceutically acceptable derivatives thereof may be formulated as aerosols for topical application, such as by inhalation (see, e.g., U.S. Pat. Nos. 4,044,126, 4,414,209, and 4,364,923, which describe aerosols for delivery of a steroid useful for treatment of inflammatory diseases, particularly asthma). These formulations for administration to the respiratory tract can be in the form of an aerosol or solution for a nebulizer, or as a microfine powder for insufflation, alone or in combination with an inert carrier such as lactose. In such a case, the particles of the formulation will, in one embodiment, have diameters of less than 50 microns, in one embodiment less than 10 microns.
The compounds may be formulated for local or topical application, such as for topical application to the skin and mucous membranes, such as in the eye, in the form of gels, creams, and lotions and for application to the eye or for intracisternal or intraspinal application. Topical administration is contemplated for transdermal delivery and also for administration to the eyes or mucosa, or for inhalation therapies. Nasal solutions of the active compound alone or in combination with other pharmaceutically acceptable excipients can also be administered.
These solutions, particularly those intended for ophthalmic use, may be formulated as 0.01%-10% isotonic solutions, pH about 5-7, with appropriate salts.
5. Compositions for Other Routes of Administration
Other routes of administration, such as transdermal patches, including iontophoretic and electrophoretic devices, and rectal administration, are also contemplated herein.
Transdermal patches, including iotophoretic and electrophoretic devices, are well known to those of skill in the art. For example, such patches are disclosed in U.S. Pat. Nos. 6,267,983, 6,261,595, 6,256,533, 6,167,301, 6,024,975, 6,010,715, 5,985,317, 5,983,134, 5,948,433, and 5,860,957.
For example, pharmaceutical dosage forms for rectal administration are rectal suppositories, capsules and tablets for systemic effect. Rectal suppositories are used herein mean solid bodies for insertion into the rectum which melt or soften at body temperature releasing one or more pharmacologically or therapeutically active ingredients. Pharmaceutically acceptable substances utilized in rectal suppositories are bases or vehicles and agents to raise the melting point. Examples of bases include cocoa butter (theobroma oil), glycerin-gelatin, carbowax (polyoxyethylene glycol) and appropriate mixtures of mono-, di- and triglycerides of fatty acids. Combinations of the various bases may be used. Agents to raise the melting point of suppositories include spermaceti and wax. Rectal suppositories may be prepared either by the compressed method or by molding. The weight of a rectal suppository, in one embodiment, is about 2 to 3 gm.
Tablets and capsules for rectal administration are manufactured using the same pharmaceutically acceptable substance and by the same methods as for formulations for oral administration.
6. Targeted Formulations
The compounds provided herein, or pharmaceutically acceptable derivatives thereof, may also be formulated to be targeted to a particular tissue, receptor, or other area of the body of the subject to be treated. Many such targeting methods are well known to those of skill in the art. All such targeting methods are contemplated herein for use in the instant compositions. For non-limiting examples of targeting methods, see, e.g., U.S. Pat. Nos. 6,316,652, 6,274,552, 6,271,359, 6,253,872, 6,139,865, 6,131,570, 6,120,751, 6,071,495, 6,060,082, 6,048,736, 6,039,975, 6,004,534, 5,985,307, 5,972,366, 5,900,252, 5,840,674, 5,759,542 and 5,709,874.
In one embodiment, liposomal suspensions, including tissue-targeted liposomes, such as tumor-targeted liposomes, may also be suitable as pharmaceutically acceptable carriers. These may be prepared according to methods known to those skilled in the art. For example, liposome formulations may be prepared as described in U.S. Pat. No. 4,522,811. Briefly, liposomes such as multilamellar vesicles (MLV's) may be formed by drying down egg phosphatidyl choline and brain phosphatidyl serine (7:3 molar ratio) on the inside of a flask. A solution of a compound provided herein in phosphate buffered saline lacking divalent cations (PBS) is added and the flask shaken until the lipid film is dispersed. The resulting vesicles are washed to remove unencapsulated compound, pelleted by centrifugation, and then resuspended in PBS.
7. Articles of Manufacture
The compounds or pharmaceutically acceptable derivatives may be packaged as articles of manufacture containing packaging material, a compound or pharmaceutically acceptable derivative thereof provided herein, which is effective for modulating α-synuclein fibril formation, or for treatment or amelioration of one or more symptoms of diseases or disorders in which α-synuclein fibril formation, is implicated, within the packaging material, and a label that indicates that the compound or composition, or pharmaceutically acceptable derivative thereof, is used for modulating α-synuclein fibril formation, or for treatment or amelioration of one or more symptoms of diseases or disorders in which α-synuclein fibril formation is implicated.
The articles of manufacture provided herein contain packaging materials. Packaging materials for use in packaging pharmaceutical products are well known to those of skill in the art. See, e.g., U.S. Pat. Nos. 5,323,907, 5,052,558 and 5,033,252. Examples of pharmaceutical packaging materials include, but are not limited to, blister packs, bottles, tubes, inhalers, pumps, bags, vials, containers, syringes, bottles, and any packaging material suitable for a selected formulation and intended mode of administration and treatment. A wide array of formulations of the compounds and compositions provided herein are contemplated as are a variety of treatments for any disease or disorder in which α-synuclein fibril formation is implicated as a mediator or contributor to the symptoms or cause.
8. Sustained Release Formulations
Also provided are sustained release formulations to deliver the compounds to the desired target (i.e. brain or systemic organs) at high circulating levels (between 10 −9 and 10 −4 M). In a certain embodiment for the treatment of Alzheimer's or Parkinson's disease, the circulating levels of the compounds is maintained up to 10 −7 M. The levels are either circulating in the patient systemically, or in one embodiment, present in brain tissue, and in a another embodiments, localized to the amyloid or α-synuclein fibril deposits in brain or other tissues.
It is understood that the compound levels are maintained over a certain period of time as is desired and can be easily determined by one skilled in the art. In one embodiment, the administration of a sustained release formulation is effected so that a constant level of therapeutic compound is maintained between 10 −8 and 10 −6 M between 48 to 96 hours in the sera.
Such sustained and/or timed release formulations may be made by sustained release means of delivery devices that are well known to those of ordinary skill in the art, such as those described in U.S. Pat. Nos. 3,845,770; 3,916,899; 3,536,809; 3,598,123; 4,008,719; 4,710,384; 5,674,533; 5,059,595; 5,591,767; 5,120,548; 5,073,543; 5,639,476; 5,354,556 and 5,733,566, the disclosures of which are each incorporated herein by reference. These pharmaceutical compositions can be used to provide slow or sustained release of one or more of the active compounds using, for example, hydroxypropylmethyl cellulose, other polymer matrices, gels, permeable membranes, osmotic systems, multilayer coatings, microparticles, liposomes, microspheres, or the like. Suitable sustained release formulations known to those skilled in the art, including those described herein, may be readily selected for use with the pharmaceutical compositions provided herein. Thus, single unit dosage forms suitable for oral administration, such as, but not limited to, tablets, capsules, gelcaps, caplets, powders and the like, that are adapted for sustained release are contemplated herein.
In one embodiment, the sustained release formulation contains active compound such as, but not limited to, microcrystalline cellulose, maltodextrin, ethylcellulose, and magnesium stearate. As described above, all known methods for encapsulation which are compatible with properties of the disclosed compounds are contemplated herein. The sustained release formulation is encapsulated by coating particles or granules of the pharmaceutical compositions provided herein with varying thickness of slowly soluble polymers or by microencapsulation. In one embodiment, the sustained release formulation is encapsulated with a coating material of varying thickness (e.g. about 1 micron to 200 microns) that allow the dissolution of the pharmaceutical composition about 48 hours to about 72 hours after administration to a mammal. In another embodiment, the coating material is a food-approved additive.
In another embodiment, the sustained release formulation is a matrix dissolution device that is prepared by compressing the drug with a slowly soluble polymer carrier into a tablet. In one embodiment, the coated particles have a size range between about 0.1 to about 300 microns, as disclosed in U.S. Pat. Nos. 4,710,384 and 5,354,556, which are incorporated herein by reference in their entireties. Each of the particles is in the form of a micromatrix, with the active ingredient uniformly distributed throughout the polymer.
Sustained release formulations such as those described in U.S. Pat. No. 4,710,384, which is incorporated herein by reference in its entirety, having a relatively high percentage of plasticizer in the coating in order to permit sufficient flexibility to prevent substantial breakage during compression are disclosed. The specific amount of plasticizer varies depending on the nature of the coating and the particular plasticizer used. The amount may be readily determined empirically by testing the release characteristics of the tablets formed. If the medicament is released too quickly, then more plasticizer is used. Release characteristics are also a function of the thickness of the coating. When substantial amounts of plasticizer are used, the sustained release capacity of the coating diminishes. Thus, the thickness of the coating may be increased slightly to make up for an increase in the amount of plasticizer. Generally, the plasticizer in such an embodiment will be present in an amount of about 15 to 30% of the sustained release material in the coating, in one embodiment 20 to 25%, and the amount of coating will be from 10 to 25% of the weight of the active material, and in another embodiment, 15 to 20% of the weight of active material. Any conventional pharmaceutically acceptable plasticizer may be incorporated into the coating.
The compounds provided herein can be formulated as a sustained and/or timed release formulation. All sustained release pharmaceutical products have a common goal of improving drug therapy over that achieved by their non-sustained counterparts. Ideally, the use of an optimally designed sustained release preparation in medical treatment is characterized by a minimum of drug substance being employed to cure or control the condition. Advantages of sustained release formulations may include: 1) extended activity of the composition, 2) reduced dosage frequency, and 3) increased patient compliance. In addition, sustained release formulations can be used to affect the time of onset of action or other characteristics, such as blood levels of the composition, and thus can affect the occurrence of side effects.
The sustained release formulations provided herein are designed to initially release an amount of the therapeutic composition that promptly produces the desired therapeutic effect, and gradually and continually release of other amounts of compositions to maintain this level of therapeutic effect over an extended period of time. In order to maintain this constant level in the body, the therapeutic composition must be released from the dosage form at a rate that will replace the composition being metabolized and excreted from the body.
The sustained release of an active ingredient may be stimulated by various inducers, for example pH, temperature, enzymes, water, or other physiological conditions or compounds.
Preparations for oral administration may be suitably formulated to give controlled release of the active compound. In one embodiment, the compounds are formulated as controlled release powders of discrete microparticles that can be readily formulated in liquid form. The sustained release powder comprises particles containing an active ingredient and optionally, an excipient with at least one non-toxic polymer.
The powder can be dispersed or suspended in a liquid vehicle and will maintain its sustained release characteristics for a useful period of time. These dispersions or suspensions have both chemical stability and stability in terms of dissolution rate. The powder may contain an excipient comprising a polymer, which may be soluble, insoluble, permeable, impermeable, or biodegradable. The polymers may be polymers or copolymers. The polymer may be a natural or synthetic polymer. Natural polymers include polypeptides (e.g., zein), polysaccharides (e.g., cellulose), and alginic acid. Representative synthetic polymers include those described, but not limited to, those described in column 3, lines 33-45 of U.S. Pat. No. 5,354,556, which is incorporated by reference in its entirety. Particularly suitable polymers include those described, but not limited to those described in column 3, line 46-column 4, line 8 of U.S. Pat. No. 5,354,556 which is incorporated by reference in its entirety.
The sustained release compositions provided herein may be formulated for parenteral administration, e.g., by intramuscular injections or implants for subcutaneous tissues and various body cavities and transdermal devices. In one embodiment, intramuscular injections are formulated as aqueous or oil suspensions. In an aqueous suspension, the sustained release effect is due to, in part, a reduction in solubility of the active compound upon complexation or a decrease in dissolution rate. A similar approach is taken with oil suspensions and solutions, wherein the release rate of an active compound is determined by partitioning of the active compound out of the oil into the surrounding aqueous medium. Only active compounds which are oil soluble and have the desired partition characteristics are suitable. Oils that may be used for intramuscular injection include, but are not limited to, sesame, olive, arachis, maize, almond, soybean, cottonseed and castor oil.
A highly developed form of drug delivery that imparts sustained release over periods of time ranging from days to years is to implant a drug-bearing polymeric device subcutaneously or in various body cavities. The polymer material used in an implant, which must be biocompatible and nontoxic, include but are not limited to hydrogels, silicones, polyethylenes, ethylene-vinyl acetate copolymers, or biodegradable polymers.
E. Evaluation of the Activity of the Compounds
The activity of the compounds provided herein as modulators of α-synuclein toxicity may be measured in standard assays (see, e.g., U.S. patent application Ser. No. 10/826,157, filed Apr. 16, 2004; U.S. Patent Application Publication No. 2003/0073610; and EXAMPLE 1 herein). The activity may be measured in a whole yeast cell assay using 384-well screening protocol and an optical density measurement. Expression of human α-synuclein in yeast inhibits growth in a copy-number dependent manner (see, e.g., Outeiro, et al. (2003) Science 302(5651):1772-5). Expression of one copy of α-syn::GFP has no effect on growth, while two copies result in complete inhibition. The cessation of growth is accompanied by a change in α-syn::GFP localization. In cells with one copy, α-syn::GFP associates with the plasma membrane in a highly selective manner. When expression is doubled, α-synuclein migrates to the cytoplasm where it forms large inclusions that are similar to Lewy bodies seen in diseased neurons.
The compounds provided herein were screened in this assay for α-synuclein toxicity rescue. Briefly, the humanized strain is exposed to compounds in 384-well plates under conditions that induce α-synuclein expression. After incubation for 48 hours, growth is measured. Compounds that inhibit toxicity will restore growth and are detected as an increase in turbidity (OD 600 ).
F. Methods of Use of the Compounds and Compositions
Provided herein are methods to inhibit or prevent α-synuclein toxicity and/or fibril formation, methods to inhibit or prevent α-synuclein fibril growth, and methods to cause disassembly, disruption, and/or disaggregation of α-synuclein fibrils and α-synuclein-associated protein deposits.
In certain embodiments, the synuclein diseases or synucleinopathies treated or whose symptoms are ameliorated by the compounds and compositions provided herein include, but are not limited to diseases associated with the formation, deposition, accumulation, or persistence of synuclein fibrils, including α-synuclein fibrils. In certain embodiments, such diseases include Parkinson's disease, familial Parkinson's disease, Lewy body disease, the Lewy body variant of Alzheimer's disease, dementia with Lewy bodies, multiple system atrophy, and the Parkinsonism-dementia complex of Guam.
In practicing the methods, effective amounts of the compounds or composition provided herein are administered. Such amounts are sufficient to achieve a therapeutically effective concentration of the compound or active component of the composition in vivo.
G. Combination Therapy
The compounds and compositions provided herein may also be used in combination with other active ingredients. In another embodiment, the compounds may be administered in combination, or sequentially, with another therapeutic agent. Such other therapeutic agents include those known for treatment or amelioration of one or more symptoms of α-synuclein diseases. Such therapeutic agents include, but are not limited to, donepezil hydrochloride (ARICEPT®), rivastigmine tartrate (EXELON®), tacrine hydrochloride (COGNEX®) and galantamine hydrobromide (REMINYL®).
The following examples are provided for illustrative purposes only and are not intended to limit the scope of the invention.
EXAMPLE 1
α-Synuclein (aS) Screening
Yeast Strains
Parental W303: MAT a/α ade2-1/ade2-1 his3-11,15/his3-11,15 leu2-3,112/leu2-3,112
trp1-1/trp1-1 ura3-1/ura3-1 can1-100/can1-100
Phenotype: Requires adenine, histidine, leucine, tryptophan, and uracil for growth. Resistant to canavanine.
Fx-109: MAT a/α ade2-1/ade2-1 his3-11,15/his3-11,15 leu2-3,112/leu2-3,112
trp1-1/trp1-1 GALp-aS-GFP::TRP1/GALp-aS-GFP::TRP1 ura3-1/ura3-1
GALp-aS-GFP::URA3/GALp-aS-GFP::URA3 can 1-100/can1-100 pdr1::KanMX/pdr1::KanMX erg6::KanMX/erg6::KanMX
Phenotype: Unable to grow on galactose due to expression of aS. Requires histidine, leucine, and adenine for growth. Resistant to canavanine and kanamycin. Hypersensitive to drugs.
Media and Reagents
Based on the genotype of the strain to be tested, choose the appropriate supplementation for the synthetic media. Strains containing integrated constructs (eg, aS) should be grown in medium which maintains selection for the construct (see below). CSM (Qbiogene) is a commercially-available amino acid mix for growing Saccharomyces cerevisiae . It can be obtained lacking one or more amino acids as required. For the aS and control strains, media lacking tryptophan and uracil (-Trp-Ura) should be used (available from Qbiogene, Inc., Carlsbad, Calif.).
To make liquid synthetic medium, mix the components listed in Table 1. After the components have dissolved, sterilize by filtration (Millipore Stericup Cat#SCGPU11RE) into a sterile bottle.
TABLE 1
Synthetic Complete Medium
Component
Vendor
Catalogue #
Size
Amount per L
Final Conc.
Yeast Nitrogen
Difco
291920
2 kg
6.7 g
0.67% (w/v)
Base without
amino acids
Carbon source: one
See
See
See
20 g
2% (w/v)
of glucose,
below
below
below
galactose,
raffinose-see Table
2
CSM: strain
Qbiogene
See
See
~0.8 g
determines type-
below
below
(according to
see Table 3
manufacturer)
MilliQ Water
—
—
1 L
—
TABLE 2
Carbon Sources
Glucose (also known
Fisher
D16-10
10
kg
20 g
2% (w/v)
as dextrose)
Galactose
SIGMA
G-0750
1
kg
20 g
2% (w/v)
Raffinose
Difco
217410
100
g
20 g
2% (w/v)
TABLE 3
CSM
CSM-Trp-Ura for
Qbiogene
4520-522
100 g
0.72 g
See
aS and control strain
Qbiogene
web page
CSM for the
Qbiogene
4500-022
100 g
0.79 g
See
parental strain
Qbiogene
web page
384-Well Screening Protocol Using Optical Density
Day 1
Innoculate an appropriate volume of SRaffinose-Trp-Ura medium with Fx-109 strain.
Incubate with shaking at 30° C. overnight until cells reach log or mid-log phase (OD 600 0.5-1.0; 0.1 OD600 corresponds to ˜1.75×10 E6 cells).
Day2
Spin down cells at room temperature, remove medium, and resuspend in an equivalent volume of SGalactose-Trp-Ura medium. Measure the OD 600 and dilute cells to 0.001. Robotically transfer 30 μl of cell suspension (MicroFill, Biotek) to each well of a 384-well plate (NUNC 242757).
Add 100 nl drug in DMSO (Cybio) to each well (final conc. 17 μg/ml drug and 0.333% DMSO)
For the positive controls add glucose to final concentrations of 0.1% and 1%. (Note: daunorubicin may be an additional control based on Biochem J. 368:131-6, 2002, but we have not tested it.)
Incubate plates at 30° C. without shaking in a humidified chamber for 48 hours.
Day 4
Read OD 650 (Envision, Perkin Elmer) and also visually inspect wells for growth of yeast culture.
Results
The compounds provided herein were assayed as described above and showed an MRC (minimum rescue concentration) of less than about 300 μM.
EXAMPLE 2
Certain compounds according to Formulae I-IX can be prepared as described below.
Preparation of Guanidines
Method 1
A mixture of guanidine-carbonate (22 g, 120 mmol) and 2-chlorobenzoxazole (7 ml, 60 mmol) in a solution of N,N-diisopropylethylamine (45 ml, 259 mmol) and DMF (100 ml) was heated at 60° C. overnight. It was evaporated and treated with water (100 ml). The ppt was collected, washed with ether and dried. Yield: 9.3 g (88%) of desired intermediate product, off-white solid. Purity: 95%.
Method 2
2-Aminobenzothiazole 1 (1 eq) and 2-methyl-2-thiopseudourea sulfate (1 eq) were mixed in a vial and heated in oil bath above the melting point of the mixture (140-220° C.) for 2 h at stirring. The mixture was allowed to cool, thoroughly triturated with hot MeOH, filtered, and washed with MeOH. The resulting grey solid product (apparently, in a mixed sulfate with S-methyl-2-thiopseudourea form), which is insoluble in organic solvents, was mixed with saturated aqueous Na 2 CO 3 and EtOAc, the water layer was extracted with EtOAc, the combined organic extracts were dried with MgSO 4 , and concentrated. The resulting crude product was purified by recrystallization from ether-hexanes or EtOAc-hexanes.
% Yield, 25-60
Method 3
Reference: Krommer, Prietzel, Weiss. 2-Benzothiazolylguanidine. Ger. Offen. (1975), 9 pp. DE 2418913 19751030 CAN 84:31048
2-Aminothiophenol, 12.5 g (0.10 mol) and water, 30 ml, were placed in a 0.25 L round-bottom flask with efficient magnetic stirrer. Concentrated aqueous HCl, 20 ml (0.22 mol) was added slowly (in ˜1-2 min) at stirring. The yellow aminothiophenol dissolved, and white precipitate of its salt formed. The mixture was heated to 70° C., and dicyandiamide, 8.4 g (0.10 mol) was added in small portions (˜10 min) at stirring.
The resulting suspension was refluxed for 20-30 min (oil bath temp 120-130° C.), then the heating was removed, the mixture allowed to cool to 60-80° C., and the solution of NaOH, 8.4 g (0.21 mol) in water, 8.4 ml, was added dropwise by pipette (slight heating observed).
The mixture was allowed to cool down, filtered, washed with water (4×20 ml), and dried under oil pump vacuum for 2 days (the solid holds nearly equal amount of water and dries very slowly). The dried light-grey solid of 2-benzothiazolylguanidine, 18.1 g (94%) was pure by HPLC and NMR.
Method 4
Stage 1
4-Phenyl-2-aminophenol, 11.4 mmol (2.10 g) was dissolved in ethanol, 30 ml, and added potassium ethyl xanthate, 11.4 mmol (1.82 g). The reaction mixture was refluxed overnight, cooled, and excess of ethanol was distilled off, then the reaction mixture was poured into crushed ice. The pH was adjusted to 5 by the addition of acetic acid. The white precipitate formed was filtered and dried to give the crude 5-phenylbenzo[d]oxazole-2-thiol, 2.32 g (90%) that was directly used in the next step without any purification.
Stage 2
5-Phenylbenzo[d}oxazole-2-thiol 2, 10 mmol (2.32 g) was dissolved in dry acetone, 40 ml, and anhydrous potassium carbonate, 12 mml (1.68 g) was added. To this reaction mixture, methyl iodide, 12 mmol (1.7 ml) was added and the mixture was refluxed at in a 70° C. bath overnight. The reaction was cooled; excess of acetone was distilled out and the residue was extracted with ethyl acetate. The combined organic layer was washed with water followed by brine water. The organic layer was dried with anhydrous sodium sulfate, and evaporation of the solvent yielded a crude product. The crude product obtained was purified by column chromatography, using 60-120 mesh silica and eluting with petroleum ether:ethyl acetate (96:4) to give compound 3, 2.15 g (87%) as off-white solid.
Stage 3
To a solution of 2-(methylthio)-5-phenylbenzo[d]oxazole 3, 9 mmol (2.15 g) in acetonitrile, 20 ml, guanidine carbonate, 18 mmol (2.11 g) and triethylamine, 36 mmol (3.60 g) was added. The reaction mixture was refluxed on an oil bath for 48 h. The reaction mixture was cooled and excess of acetonitrile was distilled out. Cold water was added and the contents were extracted with ethyl acetate (3×50 mL). The combined organic layers were washed with water followed by brine solution and dried over anhydrous sodium sulfate. Evaporation of ethyl acetate gave the crude product. The crude product obtained was purified by column chromatography over silica gel using petroleum ether: ethyl acetate [50:50] as eluent to give 0.630 g (28%) of the product as white solid.
Method 5
2-Chloroketone 1 (1 eq) 2-imino-4-thiobiuret 2 (1 eq) were dissolved in methanol or ethanol and refluxed until the product precipitates or until reaction is complete. The mixture was cooled down, and the product obtained by filtration or concentration was purified, if necessary, by recrystallization from methanol or chromatography on silica gel, eluent EtOAc-hexanes.
% Yield, 20-80
Method 6
1,1-Dibromopinacolone, 10 mmol (2.58 g) and 2-Imino-4-thiobiuret, 10 mmol (1.18 g) were mixed with 20 ml methanol and refluxed overnight. The white precipitate formed was filtered off; and the filtrate was concentrated to give 0.773 g (39%) of 3 as a cream colored solid.
Preparation of Acylguanidines
Method H
A solution of starting material 1 (1 mmol) in THF (10 ml) is cooled to −10° C. To it is added NaH (60%, 5 mmol). After 20 min stirring, a solution of acid chloride 2 (1.2 mmol) in THF (3 ml) is dropped slowly. The reaction mixture is stirred at −10° C. for 1 h, and evaporated to dry. To the residue is added water (10 ml). The mixture is shaken for a while. The insoluble solid is collected, washed with water and ether, and dried. The crude product contains ˜50% of product 3, 40% of starting material 2 and no significant di-amide formed. The product is isolated by silica gel chromatography using 20% ethyl acetate in hexanes. First band is collected, evaporated to dry to give desired product 3.
% Yield, 5-67
Method I:
Similar to method H, Yield 8%
Method J
The mono-substituted guanidine 1 (1 eq), acid 2 (1 eq), HBTU (1 eq) (or: EDCI.HCl (N-(3-Dimethylaminopropyl)-N′-ethylcarbodiimide hydrochloride) (1 eq) and HOAt (1 eq.)), were dissolved in DMF, triethylamine or diisopropylethylamine (5 eq) was added, and the mixture was stirred at rt for 15-48 h. The excess of the amine was evaporated and the mixture was purified by prep-HPLC, eluent H 2 O—CH 3 CN-TFA, 95:5:0.05 to 5:95:0.05. When necessary, analytically pure sample was obtained by second prep-HPLC purification or recrystallization from ether/hexanes.
% Yield, 0.4-81
Method K
The guanidine (2 eq) was dissolved in THF, cooled to 0° C., then acid chloride (1 eq) was added dropwise in ˜10 min at stirring under Ar atmosphere. Stirring continued at 0° C. for 1 h, then at rt overnight. The white solid formed was filtered off; the filtrate was concentrated under vacuum and recrystallized from MeOH or ether/hexanes.
% Yield, 10-30
Method L
Aminobenzothiazole 1 (eq) and isocyanate or isothiocyanate 2 (1 eq) were refluxed in acetone overnight. The product was purified by chromatography on silica gel, eluent hexanes-EtOAc (100:0 to 0:100), followed by pepr-HPLC, eluent H 2 O—CH 3 CN-TFA (95:5:0.05 to 5:95:0.05).
% Yield, 2-13
Method T
The method is the same as Method J (above), but starts from amine 1.
Method U
To the stirring suspension of imidazole 1 (1 eq) and K 2 CO 3 (100 eq) in acetone-water (3:1), dimethylsulfate (7 eq) was added and the mixture was stirred overnight and purified by prep-HPLC.
% Yield, 20
EXAMPLE 3
Compounds according to Formula III can be prepared as indicated below.
Method D
Compound 1 and compound 2 (1 equivalent) were mixed in anhydrous toluene and heated at 100° C. for 0.5 hr. Meldrum's acid (2,2-Dimethyl-[1,3]dioxane-4,6-dione) (1 equivalent) was added slowly and the solution heated at 100° C. for 2-12 hr. Upon cooling the product precipitated that was separated by filtration. The product (3) was purified by flash chromatography on silica gel (eluent, hexane:ethyl acetate, 20-50%).
% Yield, 30-80.
Method M
Stage 1
Compound 1 was dissolved in toluene and pyridine (1.2 equivalent) was added. Solution was stirred at 0° C. and compound 2 dissolved in toluene was added slowly. The solution was stirred at ambient temperature for 12 hr. Precipitated salt was separated by filtration and the filtrate was partitioned between water and ethyl acetate. The organic layer was washed with aqueous saturated sodium bicarbonate, 10% citric acid and water. Evaporation of the solvent afforded the product that was purified by crystallization from ether or hexane-ethyl acetate.
% Yield, 70-95.
Stage 2
Compound 3 was mixed with polyphosphoric acid and heated at 120° C. for 0.5 hr. The warm solution was poured onto ice-water and the precipitate separated by filtration. The product (4) was purified by column chromatography on silica gel (eluent, hexane:ethyl acetate, 20-50%).
% Yield, 5-10.
Method N
Preparation of 3-(2-Oxo-2,3,4,6,7,8-hexahydro-1H-cyclopenta[g]quinolin-4-yl)-benzonitrile
A mixture of 4-(3-Bromo-phenyl)-1,3,4,6,7,8-hexahydro-cyclopenta[g]quinolin-2-one (160 mg, 0.47 mmol) and cuprous cyanide (50.3 mg, 0.56 mmol) in N,N′-dimethylpropyleneurea was heated at 195° C. for 14 hr under an atmosphere of argon. Water was added and the product extracted with ethyl acetate. The product (12 mg) was purified by flash chromatography on silica gel (eluent, hexane:ethyl acetate, 8:2, 7:3, 6:4) followed by reverse phase HPLC (water-acetonitrile gradient, 0.05% trifluoroacetic acid, 70:30 to 10:90, 20 min, linear gradient; flow, 15 ml/min; column, Phenomenex Luna 5μ C18, 100×21.2 mm; UV 254 and 218 nm).
Method O
Preparation of 4-(3-Amino-phenyl)-3,4-dihydro-1H-benzo[h]quinolin-2-one
To a stirred suspension of 4-(3-Nitro-phenyl)-3,4-dihydro-1H-benzo[h]quinolin-2-one (1.0 g, 3.14 mmol) and 10% Pd/C (0.10 g) in ethanol (50 ml) was slowly added hydrazine hydrate (0.40 g, 12.6 mmol). The solution was refluxed for 2 hr and the catalyst separated by filtration. The filtrate was concentrated in vacuo to 20 ml and the solution stored in a refrigerator overnight. The precipitate was separated by filtration, washed with small amount of ethanol and vacuum dried to afford the product (0.77 g, 2.67 mmol).
Method P
Preparation of 4-[3-(1H-Tetrazol-5-yl)-phenyl]-3,4-dihydro-1H-benzo[h]quinolin-2-one
A mixture of 3-(2-Oxo-1,2,3,4-tetrahydro-benzo[h]quinolin-4-yl)-benzonitrile (0.50 g, 1.68 mmol), sodium azide (0.13 g, 2.0 mmol) and ammonium chloride (0.11 g, 2.01 mmol) in dimethylformamide (3.5 ml) was heated with stirring at 130° C. for 18 hr. The solvent was removed in vacuo and water was added. The solution was acidified with dilute hydrochloric acid to afford a precipitate which was separated by filtration. Crystallization from methanol afforded the title compound (0.23 g, 0.67 mmol).
Method Q
Preparation of 4-(3-Azido-phenyl)-3,4-dihydro-1H-benzo[h]quinolin-2-one
4-(3-Amino-phenyl)-3,4-dihydro-1H-benzo[h]quinolin-2-one (0.29 g, 1 mmol) was dissolved in a mixture of con. sulfuric acid (2.5 ml), water (2.5 ml) and methanol (2.5 ml). The solution was stirred at 0° C. and a solution of sodium nitrite (0.83 g, 1.2 mmol) in water (1 ml) was slowly added. The solution was stirred at 0° C. for 0.5 hr and a solution of sodium azide (0.13 g, 2 mmol) in water (1 ml) was added. The mixture was stirred at 0° C. for 0.5 hr followed by overnight stirring at ambient temperature. Water was added and the precipitate separated by filtration. The product was purified by reverse phase HPLC (0.05 g, 0.15 mmol) (water-acetonitrile gradient, 0.05% formic acid, 90:10 to 10:90, 20 min, linear gradient; flow, 15 ml/min; column, Phenomenex Luna 5μ C18, 100×21.2 mm; UV 254 and 218 nm).
Method R
Preparation of N-[3-(2-Oxo-1,2,3,4-tetrahydro-benzo[h]quinolin-4-yl)-phenyl]-acetamide
A mixture of 4-(3-Amino-phenyl)-3,4-dihydro-1H-benzo[h]quinolin-2-one (0.25 g, 0.87 mmol), acetic anhydride (1 ml) and anhydrous pyridine (1 ml) was stirred at ambient temperature overnight. Water was added and the precipitate was separated by filtration. Crystallization from methanol-acetonitrile afforded the title compound (0.06 g, 0.18 mmol).
Method S
Preparation of 4-Phenyl-1H-benzo[h]quinolin-2-one
A mixture of 4-Phenyl-3,4-dihydro-1H-benzo[h]quinolin-2-one (0.55 g, 2.0 mmol) and sulfur (0.06 g, 2 mmol) was stirred at 205° C. for 0.5 hr under a nitrogen atmosphere. A second batch of sulfur (0.06 g, 2 mmol) was added and the solution stirred for 12 hr at 205° C. The product was dissolved in hot acetic acid and filtered. The clear filtrate upon cooling deposited crystals that were separated by filtration and washed with acetic acid and water followed by vacuum drying to afford the title compound (0.08 g, 0.30 mmol).
Since modifications will be apparent to those of skill in the art, it is intended that the invention be limited only by the scope of the appended claims.
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Compounds and compositions are provided for treatment or amelioration of one or more symptoms of α-synuclein toxicity, α-synuclein mediated diseases or diseases in which α-synuclein fibrils are a symptom or cause of the disease. In one embodiment, the compounds for use in the compositions and methods are heteroaryl acylguanidines, heteroarylhydrazones, dihydropyridones, heteroaryl and aryl styryl ketones, and heteroarylpyrazoles.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention is generally related to a lift boat or jack-up rig and more particularly to the mechanism for raising and lowering the legs of a lift boat or jack-up rig.
[0003] 2. General Background
[0004] In offshore work related to the search for and production of oil and gas, a variety of vessel types are used. One type is a lift boat. A lift boat is a vessel that can elevate itself out of the water so as to provide a stable platform at the appropriate elevation to perform a number of marine construction tasks, Lift boats are equipped with retractable legs that each has a footing at the bottom. The footings contact the bottom and are of sufficient size to support the vessel on the seabed. The number of legs can vary from three to as many as six. One or more cranes are fixed to the deck of the vessel and are used to lift equipment onto or off of oil drilling or production platforms. A larger version of the lift boat called a jack-up rig typically is outfitted with drilling equipment. From this point on all mention of lift boats shall also be understood as including jack-up rigs.
[0005] At least one gear rack is typically incorporated into each leg of a lift boat. The legs of a lift boat are either constructed as a lattice type or as a tubular type. One or more pinion assemblies operate along each gear rack. A pinion assembly typically consists of a pinion, gear box, braking mechanism and either an electric or hydraulic motor. The pinion assemblies are either rigidly fixed to the vessel or can be of the floating type. As the pinions of the lift boat rotate, the lift boat is either raised out of the water or lowered toward the surface of the water depending upon the direction of pinion rotation.
[0006] The legs can be somewhat self-centering if multiple gear racks are used on the legs and if the gear racks are arranged properly. Even if the racks are ideally numbered and positioned some side loading of the legs will occur due to sea, wind, and vessel loading conditions. The current generation of lift boats employs a linear metal bearing guide to restrict leg movement. This guide system consists of metal bearing strips attached to the vessel or to the jacking apparatus. The guides may ride along the gear rack, the leg cords, or attachments to either the leg or gear rack. Smaller lift boats have leg towers constructed from tubular members and have tubular legs with outside diameters slightly smaller than the inside diameters of the leg towers. The leg tower is the sole guide. The shortcomings of these types of guide apparatus are that friction between the leg and guides increases the jacking force required to operate the lift boat and much of the lubricant used on the guides is dropped into the sea.
SUMMARY OF THE INVENTION
[0007] The present invention addresses the above needs in a straightforward manner. What is provided is an apparatus for efficiently guiding the legs of a lift boat. Roller assemblies are used to guide the legs. The rollers may be placed at any location or in any number either vertically or around the leg to adequately center the leg. The roller can either have a metal surface that rolls along the leg or be coated with a resilient material. The base of the roller can either be rigidly mounted to the vessel or incorporate resilient material between the roller and the vessel. A means of adjusting the clearance between the leg and roller may be incorporated in the roller assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] For a further understanding of the nature and objects of the present invention reference should be made to the following description, taken in conjunction with the accompanying drawings in which like parts are given like reference numerals, and wherein:
[0009] [0009]FIG. 1 is an isometric view of a lift boat.
[0010] [0010]FIG. 2 is a detail view of a jacking and guide apparatus.
[0011] [0011]FIG. 3 is an isometric view of the guide roller assembly.
[0012] [0012]FIG. 4 is an exploded view of the guide roller assembly.
[0013] [0013]FIG. 5 illustrates an alternate embodiment of the invention.
[0014] [0014]FIG. 6 is a detail view of the alternate embodiment of FIG. 5.
[0015] [0015]FIG. 7 is a detail view of another alternate embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0016] Referring to FIG. 1, it is seen that a typical lift boat is generally indicated by the numeral 10 . For ease of illustration the lift boat's deckhouse, cranes and all deck equipment have been omitted. The lift boat is generally comprised of a hull 12 and a plurality of legs 14 . The hull 12 is a buoyant hull that has sufficient buoyancy to support the hull, legs, and any equipment placed on the hull. As seen in FIG. 1, the lift boat is elevated above the water's surface 30 . As seen in FIG. 2 each leg 14 is received through a leg well 34 provided near each corner of the hull 12 . The outer diameter of each leg 14 is less than the diameter of the leg well 34 so as to be movable through the hull 12 . Although only a tubular column 20 is shown, it should be understood that the legs 14 may be formed from either a tubular or lattice column. Each leg 14 is provided with a rack 22 and a footing 24 . The legs 14 may have singular or multiple racks 22 . The leg 14 is raised and lowered through the hull 12 by a pinion tower 18 . Each rack 22 may have singular or multiple pinions 32 . Multiple pinion towers 18 may be separately attached to the hull 12 or may be integrated into a unit attached to the hull 12 . The footings 24 are of sufficient size to provide resistance to the seabed 28 to allow the pinion tower 18 to elevate the hull 12 above the surface of the water.
[0017] Referring to FIG. 2- 4 , it is seen that the invention is generally indicated by the numeral 26 . Guide roller apparatus 26 is generally comprised of a support box 36 , a pivot arm 38 and a roller 40 .
[0018] The support box 36 is formed from two or more support box side plates 42 that are attached to a support box back plate 46 and a support box bottom plate 44 . A support box pin 48 connects the pivot arm 38 to the support box 36 . A keeper 50 prevents the support box pin 48 from sliding out of the support box 36 . The keeper 50 is attached to the support box 36 by any suitable means such as by welding, mechanical fastener, or by the use of an adhesive.
[0019] The pivot arm 38 is of suitable shape to transfer forces from the leg 14 to the hull 12 . The pivot arm 38 is formed from two or more pivot arm side plates 52 that are attached to a pivot arm back plate 68 . A pivot arm pin 56 connects the roller 40 to the pivot arm side plate 52 . A keeper 51 prevents the pivot arm pin 56 from sliding out of the pivot arm side plates 52 .
[0020] The roller 40 is of suitable shape to transfer forces from the leg 14 to the hull 12 . A bushing 58 , an inner core 60 , and an outer core 62 are assembled together to make up the roller 40 . The bushing 58 is of suitable shape and material to allow it, the inner core 60 , and the outer core 62 to rotate around pin 56 . The bushing 58 may be constructed of non-lubricated or lubricated material. The bushing 58 is attached to the inner core 60 by interference fit, bonded, or keyed to prevent relative movement. The inner core is constructed of suitable rigid material such as steel and attached to the outer core 62 by interference fit or bonded to prevent relative movement. The outer core 62 is formed from a suitable resilient material such as neoprene.
[0021] One or more spacer plates 64 are of suitable shape and material to transfer forces from the leg 14 to the hull 12 . Resilient plate 66 is of suitable shape and material to transfer forces form the leg 14 to the hull 12 . Spacer plates 64 may be of varying thickness and number to adjust the nominal distance between the roller 40 and the leg 14 from a clearance to a compressed pre-load. In a preload condition the resilient outer roller 62 and the resilient plate 66 are deformed so that during normal operating conditions there is no clearance between roller 40 and leg 14 .
[0022] The guide roller apparatus 26 may be securely attached to either the hull 12 , pinion tower 18 or, as seen in FIG. 2, to a guide roller tower 16 . The guide roller apparatus 26 may be the sole means of guiding the leg 14 or may be used in conjunction with bearing strips or any other suitable guide apparatus. The guide roller apparatus 26 may be set to a desired clearance or pre-load to the leg column 20 , rack 22 , or any attachment to either. The roller apparatus 26 is of sufficient size, number and location to adequately restrict the leg 14 to movement with the hull 12 . The guide roller tower 16 may be attached directly to the hull 12 or incorporated into the hull 12 , pinion tower 18 or other parts of the lift boat 10 .
[0023] In operation, as the legs 14 are moved up or down through the hull 12 , the guide roller apparatus 26 on each leg 14 confines each leg 14 to a near perpendicular orientation relative to the deck of the hull 12 . The advantage this provides is that it prevents any out of alignment movement, which decreases the efficiency of the driving system and increases the possibility of damage.
[0024] An alternate embodiment of the invention is generally indicated by numeral 70 in FIG. 5 and 6 . Track guide apparatus 70 is generally comprised of track 92 , rail structure 90 , idlers 76 and rollers 86 . For ease of illustration, the hull and pinion tower are not shown.
[0025] A leg tower 74 is attached to the lift boat and is sized to allow movement of the leg 14 therethrough. The leg tower 74 is provided with an elongated opening 72 . Track guide apparatus 70 is attached to the leg tower 74 and contacts the leg 20 through the elongated opening 72 in the leg tower.
[0026] As best seen in FIG. 6, the track 92 is comprised of link plates 88 , link pins 78 , and track pads 84 traveling around idlers 76 . The force exerted upon the track 92 by the leg 20 is transferred to the rail structure 90 via the rollers 86 . The rollers may be of a similar design as shown in FIG. 4 or of any other design suitable to transfer the force. The rail structure generally indicated by numeral 90 is comprised of a rail 82 and rail flanges 80 . The rail flanges 80 are attached to the leg tower 74 .
[0027] [0027]FIG. 7 illustrates a second alternate embodiment of the invention. The alternate track guide apparatus is generally indicated by the numeral 102 . The link 94 and pins 96 are similar to the link and pin shown in FIG. 5 and 6 . Roller 98 contacts the rail 100 and the leg, not shown. Roller 98 may be incorporated with the pin 96 as one component. For clarity, the rail flanges that attach the rail to the tower are not shown.
[0028] Because many varying and differing embodiments may be made within the scope of the inventive concept herein taught and because many modifications may be made in the embodiment herein detailed in accordance with the descriptive requirement of the law, it is to be understood that the details herein re to be interpreted as illustrative and not in a limiting sense.
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An apparatus for efficiently guiding the legs of a lift boat. Roller assemblies are used to guide the legs. The rollers may be placed at any location or in any number either vertically or around the leg to adequately center the leg. The roller can either have a metal surface that rolls along the leg or be coated with a resilient material. The base of the roller can either be rigidly mounted to the vessel or incorporate resilient material between the roller and the vessel. A means of adjusting the clearance between the leg and roller may be incorporated in the roller assembly.
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FIELD OF THE INVENTION
[0001] This invention relates to fabrication processes for semiconductor devices.
BACKGROUND
[0002] Silicon carbide (SiC) has a large energy band gap and high breakdown field. As such, SiC is an attractive material for electronic devices operating at high temperatures and high power. SiC also exhibits mechanical properties and chemical inertness which are useful in micro-electromechanical systems (MEMS) as well as nano-electromechanical systems (NEMS) for applications in harsh environments. SiC based devices are therefore particularly attractive for use as high-temperature sensors and actuators.
[0003] Additionally, SiC has a high acoustic velocity and extremely stable surfaces. Thus, SiC is a promising structural material for fabricating ultra-high frequency micromechanical signal processing systems. The highly stable physicochemical properties of SiC also improve the performance of high-frequency resonators as the surface-to-volume ratio increases when the resonator frequency scales into the GHz ranges.
[0004] One of the challenges in fabricating SiC devices is related to the selective etching of SiC films or SiC bulk materials. Unlike silicon (Si), SiC is not etched significantly by most acids and bases at temperatures less than about 600° C. Most wet etching processes, however, are not easily effected at temperatures greater than about 600° C. Non-standard techniques such as laser-assisted photo-electrochemical etching have been developed, but such techniques require special equipment and exhibit poor lateral dimension control.
[0005] Traditional fabrication processes incorporating photoresist etch masks are also problematic. Primary etch gasses that are used in SiC etching include chlorine (Cl 2 ) and hydrogen bromide (HBr). The photoresist material, however, exhibits poor selectivity compared to SiC when exposed to traditional etch gases.
[0006] What is needed is a method of manufacturing a device incorporating a masking material which exhibits increased selectivity compared with traditional masking materials. What is further needed is a method of manufacturing a device incorporating a masking material which exhibits increased selectivity when exposed to traditional SiC etching gases.
SUMMARY
[0007] In accordance with one embodiment of the present invention, there is provided a method of etching a device that includes providing a silicon carbide substrate, forming a silicon nitride layer on a surface of the silicon carbide substrate, forming a silicon carbide layer on a surface of the silicon nitride layer, forming a silicon dioxide layer on a surface of the silicon carbide layer, forming a photoresist mask on a surface of the silicon dioxide layer, and etching the silicon dioxide layer through the photoresist mask.
[0008] In accordance with another embodiment of the present invention, there is provided a method of etching a semiconductor device including providing a substrate, forming an etch stop layer on a surface of the substrate, forming a silicon carbide layer on a surface of the etch stop layer, forming a hard mask layer on a surface of the silicon carbide layer, forming a photoresist mask on the hard mask layer, and etching the silicon carbide layer through the hard mask layer and the photoresist mask.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 shows a flow chart of an SiC etching portion of a process for manufacturing a device in accordance with principles of the present invention;
[0010] FIG. 2 shows a cross-sectional view of a substrate, which in this embodiment is a SiC substrate, which may be used in a device in accordance with principles of the present invention;
[0011] FIG. 3 shows a device including the substrate of FIG. 2 with an etch stop layer, which may include Si 3 N 4 , formed on the upper surface of the substrate;
[0012] FIG. 4 shows the device of FIG. 3 with a SiC layer formed on the upper surface of the etch stop layer of FIG. 3 ;
[0013] FIG. 5 shows the device of FIG. 4 with a hard mask layer, which in this embodiment includes SiO 2 , formed on the SiC layer of FIG. 4 ;
[0014] FIG. 6 shows the device of FIG. 5 with a photoresist mask formed on the upper surface of the hard mask layer of FIG. 5 ;
[0015] FIG. 7 shows the device of FIG. 6 with the hard mask layer etched beneath the openings of the photoresist mask to expose portions of the upper surface of the SiC layer in accordance with principles of the present invention;
[0016] FIG. 8 shows the device of FIG. 7 with the SiC layer etched beneath the openings of the photoresist mask to expose portions of the upper surface of the etch stop layer in accordance with principles of the present invention;
[0017] FIG. 9 shows the device of FIG. 8 with the etch stop layer etched beneath the openings of the photoresist mask to expose portions of the upper surface of the substrate in accordance with principles of the present invention;
[0018] FIG. 10 shows the device of FIG. 9 with the remainder of the photoresist mask removed to expose the remainder of the upper surface of the hard mask layer in accordance with principles of the present invention; and
[0019] FIG. 11 shows the device of FIG. 10 with the remainder of the upper surface of the hard mask layer removed to expose the remainder of the upper surface of the SiC layer in accordance with principles of the present invention.
DESCRIPTION
[0020] For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and described in the following written specification. It is understood that no limitation to the scope of the invention is thereby intended. It is further understood that the present invention includes any alterations and modifications to the illustrated embodiments and includes further applications of the principles of the invention as would normally occur to one skilled in the art to which this invention pertains.
[0021] FIG. 1 shows a flow chart 100 of SiC etching portion of a manufacturing process for a device in accordance with principles of the present invention. The process 100 of FIG. 1 begins at step 102 and a substrate is provided at 104 . At step 106 , an etch stop layer is formed on the surface of the substrate followed by formation of a SiC layer on the etch stop layer at the step 108 . A hard mask is then formed on the SiC layer at step 110 and a photoresist mask is patterned on the hard mask at step 112 .
[0022] Etching of the device begins with etching of the hard mask layer through the photoresist mask at the step 114 . Next, the SiC layer is etched at the step 116 through the photoresist mask and the hard mask layer. The etch stop layer is then etched at the step 118 .
[0023] When the desired etching is concluded, the photoresist mask is removed at the step 120 followed by the removal of the hard mask layer at the step 122 . The process then ends at the step 124 . After the process shown in FIG. 1 is complete, further processing of the device may be performed.
[0024] One example of the process of FIG. 1 is shown in FIGS. 2-11 . A substrate 130 is shown if FIG. 2 . The substrate 130 may either be a SiC substrate or a substrate having a layer of SiC formed thereon. Next, FIG. 3 shows an etch stop layer 132 formed on the upper surface 134 of the substrate 130 . The etch stop layer 132 preferably includes silicon nitride (Si 3 N 4 ). Next, a layer 136 of SiC is formed on the upper surface 138 of the etch stop layer 132 as shown in FIG. 4 and a hard mask layer 140 is formed on the upper surface 142 of the SiC layer 136 as shown in FIG. 5 . The hard mask layer 140 in this embodiment includes silicon dioxide (SiO 2 ).
[0025] FIG. 6 shows a photoresist mask 144 in position on the upper surface 146 of the hard mask layer 140 . The photoresist mask 144 may be patterned to include a number of openings 148 . The openings 148 may be of any desired form such as circles, rectangles, etc. Portion of the upper surface 146 of the hard mask layer 140 are exposed through the openings 148 .
[0026] Etching of the device may then be performed using an etching gas which preferably includes Cl 2 , HBr or both Cl 2 and HBr. The etching gas contacts the hard mask layer 140 through the openings 148 thereby etching the material directly beneath the openings 148 and generating a via 150 through the hard mask layer 140 to expose the SiC layer 136 as shown in FIG. 7 .
[0027] Continued exposure to etching gases results in the etching of the SiC layer 136 . The hard mask layer 140 is exposed to the etching gases about the vias 150 . The SiC layer 136 , however, is more rapidly etched by the etch gases than the material used to form the hard mask layer 140 . In the embodiment of FIGS. 2-11 , the selectivity ratio of the SiC layer to the SiO 2 hard mask layer is about 6:1. Accordingly, the predominant effect of the etch gas is to extend the via 150 through the SiC layer 136 to expose the upper surface 138 of the etch stop layer 132 as shown in FIG. 8 .
[0028] Continued exposure to etching gases results in the etching of the etch stop layer 132 . The selectivity ratio of SiC to the Si 3 N 4 used in this embodiment is about 1.4:1. Accordingly, the via 150 widens as the etch stop layer 132 is etched, particularly in the SiC layer 136 . Etching concludes when the upper surface 134 of the substrate 130 is exposed to the desired extent as shown in FIG. 9 .
[0029] At this point, the photoresist mask 144 is no longer needed. Accordingly, any remnant of the photoresist mask 144 is removed using any desired process leaving the remainder of the upper surface 146 of the hard mask layer 140 exposed as shown in FIG. 10 . The remainder of the hard mask layer 140 is likewise removed using any desired process leaving the remainder of the upper surface 142 of the SiC layer 136 exposed as shown in FIG. 11 .
[0030] While the invention has been illustrated and described in detail in the drawings and foregoing description, the same should be considered as illustrative and not restrictive in character. It is understood that only the preferred embodiments have been presented and that all changes, modifications and further applications that come within the spirit of the invention are desired to be protected.
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A method of etching a device in one embodiment includes providing a silicon carbide substrate, forming a silicon nitride layer on a surface of the silicon carbide substrate, forming a silicon carbide layer on a surface of the silicon nitride layer, forming a silicon dioxide layer on a surface of the silicon carbide layer, forming a photoresist mask on a surface of the silicon dioxide layer, and etching the silicon dioxide layer through the photoresist mask.
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This application claims priority to U.S. Ser. No. 60/086,396 filed May 22, 1998.
BACKGROUND TO THE INVENTION
Numerous microorganisms have the ability to accumulate intracellular reserves of PHA polymers. Poly [(R)-3-hydroxyalkanoates] (PHAs) are biodegradable and biocompatible thermoplastic materials, produced from renewable resources, with a broad range of industrial and biomedical applications (Williams and Peoples, 1996, CHEMTECH 26, 38-44). Around 100 different monomers have been incorporated into PHA polymers, as reported in the literature (Steinbüchel and Valentin, 1995, FEMS Microbiol. Lett. 128; 219-228) and the biology and genetics of their metabolism has recently been reviewed (Huisman and Madison, 1998, Microbiology and Molecular Biology Reviews, 63: 21-53).
To date, PHAs have seen limited commercial availability, with only the copolymer poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV) being available in development quantities. This copolymer has been produced by fermentation of the bacterium Ralstonia eutropha. Fermentation and recovery processes for other PHA types have also been developed using a range of bacteria including Azotobacter, Alcaligenes latus, Comamonas testosterone and genetically engineered E. coli and Klebsiella and have recently been reviewed (Braunegg et al., 1998, Journal of Biotechnology 65: 127-161; Choi and Lee, 1999, Appl. Microbiol. Biotechnol. 51: 13-21). More traditional polymer synthesis approaches have also been examined, including direct condensation and ring-opening polymerization of the corresponding lactones (Jesudason and Marchessault, 1994, Macromolecules 27: 2595-2602).
Synthesis of PHA polymers containing the monomer 4-hydroxybutyrate (PHB4HB, Doi, Y. 1995, Macromol. Symp. 98, 585-599) or 4-hydroxyvalerate and 4-hydroxyhexanoate containing PHA polyesters have been described (Valentin et al., 1992, Appl. Microbiol. Biotechnol. 36, 507-514 and Valentin et al., 1994, Appl. Microbiol. Biotechnol. 40, 710-716). These polyesters have been manufactured using methods similar to that originally described for PHBV in which the microorganisms are fed a relatively expensive non-carbohydrate feedstock in order to force the incorporation of the monomer into the PHA polyester. The PHB4HB copolymers can be produced with a range of monomer compositions which again provides a range of polymer (Saito, Y, Nakamura, S., Hiramitsu, M. and Doi, Y., 1996, Polym. Int. 39: 169).
PHA copolymers of 3-hydroxybutyrate-co-3-hydroxypropionate have also been described (Shimamura et. al., 1994, Macromolecules 27: 4429-4435; Cao et. al., 1997, Macromol. Chem. Phys. 198: 3539-3557). The highest level of 3-hydroxypropionate incorporated into these copolymers 88 mol % (Shimamura et. al., 1994, Macromolecules 27: 4429-4435).
PHA terpolymers containing 4-hydroxyvalerate have been produced by feeding a genetically engineered Pseudomonas putida strain on 4-hydroxyvalerate or levulinic acid which resulted in a three component PHA, Poly(3-hydroxybutyrate-co-3-hydroxyvalerate-4-hydroxyvalerate) (Valentin et. al., 1992, Appl. Microbiol. Biotechnol. 36: 507-514; Steinbüchel and Gorenflo, 1997, Macromol. Symp. 123: 61-66). It is desirable to develop biological systems to produce two component polymers comprising 4-hydroxyvalerate or poly(4-hydroxyvalerate) homopolymer. The results of Steinbüchel and Gorenflo (1997, Macromol. Symp. 123: 61-66) indicate that Pseudomonas putida has the ability to convert levulinic acid to 4-hydroxyvalerate.
Hein et al. (1997) attempted to synthesize poly-4HV using transgenic Escherichia coli strain XL1-Blue but were unsuccessful. These cells carried a plasmid which permitted expression of the A. eutrophus PHA synthase and the Clostridium kluyveri 4-hydroxybutyryl-CoA transferase genes. When the transgenic E. coli were fed 4HV, □-valerolactone, or levulinic acid, they produced only a small amount of PHB homopolymer.
It is clearly desirable for industrial reasons to be able to produce a range of defined PHA homopolymer, copolyer and terpolymer compositions. To accomplish this, it is desirable to be able to control the availability of the individual enzymes in the corresponding PHA biosynthetic pathways.
It is therefore an object of the present invention to provide a range of defined PHA homopolymer, copolyer and terpolymer compositions.
It is another object of the present invention to provide a method and materials to control the availability of the individual enzymes in the corresponding PHA biosynthetic pathways.
SUMMARY OF THE INVENTION
Several novel PHA polymer compositions produced using biological systems include monomers such as 3-hydroxybutyrate, 3-hydroxypropionate, 2-hydroxybutyrate, 3-hydroxyvalerate, 4-hydroxybutyrate, 4-hydroxyvalerate and 5-hydroxyvalerate. These PHA compositions can readily be extended to incorporate additional monomers including, for example, 3-hydroxyhexanoate, 4-hydroxyhexanoate, 6-hydroxyhexanoate or other longer chain 3-hydroxyacids containing seven or more carbons. This can be accomplished by taking natural PHA producers and mutating through chemical or transposon mutagenesis to delete or inactivate genes encoding undesirable activities. Alternatively, the strains can be genetically engineered to express only those enzymes required for the production of the desired polymer composition. Methods for genetically engineering PHA producing microbes are widely known in the art (Huisman and Madison, 1998, Microbiology and Molecular Biology Reviews, 63: 21-53). These polymers have a variety of uses in medical, industrial and other commercial areas.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic of the pathway from levulinic acid to poly-4-hydroxyvalerate.
FIG. 2 is a schematic of a construct of plasmid pFS16, which includes the lacI (inducer) gene, ampicillin resistance gene, and hbcT gene.
FIG. 3 is a schematic of a construct of plasmid pFS30, which includes the lacI (inducer) gene, ampicillin resistance gene, polyhydroxyalkanoate polymerase (phaC) gene, and hbcT gene.
DETAILED DESCRIPTION OF THE INVENTION
Several novel PHA polymer compositions have been produced using biological systems to incorporate monomers such as 3-hydroxybutyrate, 3-hydroxypropionate, 2-hydroxybutyrate, 3-hydroxyvalerate, 4-hydroxybutyrate, 4-hydroxyvalerate and 5-hydroxyvalerate. These PHA compositions can readily be extended to incorporate additional monomers including, for example, 3-hydroxyhexanoate, 4-hydroxyhexanoate, 6-hydroxyhexanoate or other longer chain 3-hydroxyacids containing seven or more carbons. Techniques and procedures to engineer transgenic organisms that synthesize PHAs containing one or more of these monomers either as sole constituent or as co-monomer have been developed. In these systems the transgenic organism is either a bacterium eg. Escherichia Coli, K. pneumoniae, Ralstonia eutropha (formerly Alcaligenes eutrophus ), Alcaligenes latus or other microorganisms able to synthesize PHAs, or a higher plant or plant component, such as the seed of an oil crop (Brassica, sunflower, soybean, corn, safflower, flax, palm or coconut or starch accumulating plants (potato, tapioca, cassava).
It is crucial for efficient PHA synthesis in recombinant E. coli strains that the expression of all the genes involved in the pathway be adequate. To this end, the genes of interest can be expressed from extrachromosomal DNA molecules such as plasmids, which intrinsically results in a copy number effect and consequently high expression levels, or, more preferably, they can be expressed from the chromosome. For large scale fermentations of commodity type products it is generally known that plasmid-based systems are unsatisfactory due to the extra burden of maintaining the plasmids and the problems of stable expression. These drawbacks can be overcome using, chromosomally encoded enzymes by improving the transcriptional and translational signals preceding the gene of interest such that expression is sufficient and stable.
The biological systems must express one or more enzymes as required to convert the monomers into polymers. Suitable substrates include 3-hydroxybutyrate, 3-hydroxypropionate, 2-hydroxybutyrate, 3-hydroxyvalerate, 4-hydroxybutyrate, 4-hydroxyvalerate, 5-hydroxyvalerate, 3-hydroxyhexanoate, 4-hydroxyhexanoate, 6-hydroxyhexanoate and other longer chain 3-hydroxyacids containing seven or more carbons. These enzymes include polyhydroxyalkanoate synthase, acyl-CoA transferase and hydroxyacyl CoA transferase, and hydroxyacyl CoA synthetase. These enzymes can be used with these substrates to produce in a biological system such as bacteria, yeast, fungi, or plants, polymer such as poly(3-hydroxybutyrate-co-4-hydroxyvalerate), poly(4-hydroxyvalerate), poly(3-hydroxypropionate-co-5-hydroxyvalerate), poly(2-hydroxybutyrate), poly(2-hydroxybutyrate-co-3-hydroxybutyrate), and poly(3-hydroxypropionate).
Genes encoding the required enzymes can be acquired from multiple sources. U.S. Pat. Nos. 5,798,235 and 5,534,432 to Peoples, et al., describe polyhydroxyalkanoate synthetase, reductase and thiolase. A 4-hydroxybutyryl CoA transferase gene from C. aminobutyricum is described by Willadsen and Buckel, FEMS Microbiol. Lett. (1990) 70: 187-192) or from C. kluyveri is described by Söhling and Gottschalk, 1996, J. Bacteriol. 178, 871-880). An acyl coenzyme A synthetase from Neurospora crassa is described by Hii and Courtright, J. Bacteriol. 1982. 150(2), 981-983. A hydroxyacyl transferase from Clostridium is described by Hofmeister and Bucker, Eur. J. Biochem. 1992, 206(2), 547-552.
It is important for efficient PHA production that strains do not lose the capability to synthesize the biopolymer for the duration of the inoculum train and the production run. Loss of any of the pha genes results in loss of product. Both are undesirable and stable propagation of the strain is therefore required. Merely integrating the gene encoding the transferase or synthase may not result in significant polymer production. Enzyme expression can be enhanced through alteration of the promoter region or mutagenesis or other known techniques, followed by screening for polymer production. Growth and morphology of these recombinant PHA producers is not compromised by the presence of pha genes on the chromosome.
The present invention will be further understood by reference to the following non-limiting examples.
EXAMPLE 1
Poly(3HB-co-4HV) from 4-hydroxyvalerate and Glucose in E. coli.
Construction of pFS16
The plasmid pTrcN is a derivative of pTrc99a (Pharmacia; Uppsala, Sweden); the modification that distinguishes pTrcN is the removal of the Ncol restriction site by digestion with NcoI, treatment with T4 DNA polymerase, and self-ligation. The orfZ gene encoding the 4-hydroxybutyryl-CoA transferase from Clostridium kluyveri was amplified using the polymerase chain reaction (PCR) and a kit from Perkin Elmer (Foster City, Calif.) using plasmid pCK3 (Söhling and Gottschalk, 1996, J. Bacteriol. 178: 871-880) as the target DNA and the following oligonucleotide primers:
5′-TCCCCTAGGATTCAGGAGGTTTTTATGGAGTGGGAAGAGATATATAAAG -3′
(orfZ 5′ AvrII)
5′-CCTTAAGTCGACAAATTCTAAAATCTCTTTTTAAATTC-3′
(orfZ 3′ SalI)
The resulting PCR product was digested with AvrII and SalI and ligated to pTrcN that had been digested with XbaI (which is compatible with AvrII) and SalI to form plasmid pFS16 such that the 4-hydroxybutyryl-CoA transferase can be expressed from the IPTG (isopropyl-β-D-glucopyranoside)—inducible trcpromoter.
Construction of pFS30.
The plasmid pFS30 was derived from pFS16 by adding the Ralstonia eutropha PHA synthase (phaC) gene (Peoples and Sinskey, 1989. J. Biol. Chem. 264:15298-15303) which had been modified by the addition of a strong E. coli ribosome binding site as described by (Gerngross et. al., 1994. Biochemistry 33: 9311-9320). The plasmid pAeT414 was digested with XmaI and StuI so that the R. eutropha promoter and the structural phaC gene were present on one fragment. pFS16 was cut with BamHI, treated with T4 DNA polymerase to create blunt ends, then digested with XmaI. The two DNA fragments thus obtained were ligated together to form pFS30. In this construct the PHB synthase and 4-hydroxybutyryl-CoA transferase are expressed from the A. eutrophus phbC promoter (Peoples and Sinskey, 1989. J. Biol. Chem. 264:15298-15303). Other suitable plasmids expressing PHB synthase and 4-hydroxybutyryl-CoA transferase have been described (Hein et. al., 1997, FEMS Microbiol. Lett. 153: 411-418; Valentin and Dennis, 1997, J. Biotechnol. 58 :33-38).
E. coli MBX769 has a PHA synthase integrated into its chromosome. This strain is capable of synthesizing, poly(3-hydroxybutyrate) (PUB) from glucose with no extrachromosomal genes present. MBX 769 is also deficient in fadR, the repressor of the fatty-acid-degradation pathway and effector of many other cellular functions, it is deficient in rpoS, a regulator of stationary-phase gene expression, and it is deficient in atoA, one subunit of the acetoacetyl-CoA transferase. MBX769 also expresses atoC, a positive regulator of the acetoacetate system, constitutively.
E. coli MBX769 carrying the plasmid pFS16 (FIG. 2 ), which permitted the expression of the Clostridium kluyveri 4-hydroxybutyryl-CoA transferase, was precultured at 37° C. in 100 mL of LB medium containing 100 μg/mL sodium ampicillin in a 250-mL Erlenmeyer flask with shaking at 200 rpm. The cells were centrifuged at 5000 g for 10 minutes to remove them from the LB medium after 16 hours, and they were resuspended in 100 mL of a medium containing, per liter: 4.1 or 12.4 g sodium 4-hydroxyvalerate (4HV); 5 g/L sodium 4-hydroxybutyrate (4HB); 2 g glucose; 2.5 g LB broth powder (Difco; Detroit, Mich.); 50 mmol potassium phosphate, pH 7; 100 μg/mL sodium ampicillin; and 0.1 mmol isopropyl-β-D-thiogalactopyranoside (IPTG). The sodium 4-hydroxyvalerate was obtained by saponification of γ-valerolactone in a solution of sodium hydroxide. The cells were incubated in this medium for 3 days with shaking at 200 rpm at 32° C. in the same flask in which they had been precultured. When 4.1 g/L sodium 4-hydroxyvalerate was present initially, the cells accumulated a polymer to 52.6% of the dry cell weight that consisted of 63.4% 3HB units and 36.6% 4HB units but no 4HV units.
When 12.4 g/L sodium 4HV was present initially, the cells accumulated a polymer to 45.9% of the dry cell weight that consisted of 95.5% 3HB units and 4.5% 4HV units but no detectable 4HB units. The identity of the PHB-co-4HV polymer was verified by nuclear magnetic resonance (NMR) analysis of the solid product obtained by chloroform extraction of whole cells followed by filtration, ethanol precipitation of the polymer from the filtrate, and washing of the polymer with water. It was also verified by gas chromatographic (GC) analysis, which was carried out as follows. Extracted polymer (1-20 mg) or lyophilized whole cells (15-50 mg) were incubated in 3 mL of a propanolysis solution consisting of 50% 1,2-dichloroethane, 40% 1-propanol, and 10% concentrated hydrochloric acid at 100° C. for 5 hours. The water-soluble components of the resulting mixture were removed by extraction with 3 mL water. The organic phase (1 μL at a split ratio of 1:50 at an overall flow rate of 2 mL/min) was analyzed on an SPB-1 fused silica capillary GC column (30 m; 0.32 mm ID; 0.25 μm film; Supelco; Bellefonte, Pa.) with the following temperature profile: 80° C., 2 min; 10° C. per min to 250° C.; 250° C., 2 min. The standard used to test for the presence of 4HV units in the polymer was γ-valerolactone, which, like 4-hydroxyvaleric acid, forms propyl 4-hydroxyvalerate upon propanolysis. The standard used to test for 3HB units in the polymer was PHB.
EXAMPLE 2
Poly(4HV) from 4-hydroxyvalerate in E. coli
Escherichia coli MBX1177 is not capable of synthesizing poly(3-hydroxybutyrate) (PHB) from glucose. MBX1177 is a spontaneous mutant of strain DH5□ that is able to use 4-hydroxybutyric acid as a carbon source. MBX1177 carrying the plasmid pFS30 (FIG. 2 ), which permitted the expression of the Clostridium kluyveri 4HB-CoA transferase and the Ralstonia eutropha PHA synthase, was precultured at 37° C. in 100 mL of LB medium containing 100 μg/mL sodium ampicillin.
The cells were centrifuged at 5000 g for 10 minutes to remove them from the LB medium after 16 hours, and they were resuspended in 100 mL of a medium containing, per liter: 5 g sodium 4-hydroxyvalerate (4HV); 2 g glucose; 2.5 g LB broth powder; 100 mmol potassium phosphate, pH 7; 100 μg/mL sodium ampicillin; and 0.1 mmol IPTG. The cells were incubated in this medium for 3 days with shaking at 200 rpm at 30° C. in the same flask in which they had been precultured.
The cells accumulated a polymer to 0.25% of the dry cell weight that consisted of 100% 4HV units. The identity of the poly(4HV) polymer was verified by GC analysis of whole cells that had been washed with water and propanolyzed in a mixture of 50% 1,2-dichloroethane, 40% 1-propanol, and 10% concentrated hydrochloric acid at 100° C. for 5 hours, with γ-valerolactone as the standard.
EXAMPLE 3
Poly(3HB-co-2HB) from 2-hydroxybutyrate and Glucose in E. coli
E. coli MBX769 carrying the plasmid pFS16 was precultured at 37° C. in 100 mL of LB medium containing 100 μg/mL sodium ampicillin in a 250-mL Erlenmeyer flask with shaking at 200 rpm. The cells were centrifuged at 5000 g for 10 minutes to remove them from the LB medium after 16 hours, and they were resuspended in 100 mL of a medium containing, per liter: 5 g sodium 2-hydroxybutyrate (2HB); 2 g glucose; 2.5 g LB broth powder; 50 mmol potassium phosphate, pH 7; 100 μg/mL sodium ampicillin; and 0.1 mmol IPTG. The cells were incubated in this medium for 3 days with shaking at 150 rpm at 33° C. in the same flask in which they had been precultured. The cells accumulated a polymer to 19.0% of the dry cell weight that consisted of 99.7% 3HB units and 0.3% 2HB units. The identity of the poly(3HB-co-2HB) polymer was verified by GC analysis of the solid product obtained by chloroform extraction of whole cells followed by filtration, ethanol precipitation of the polymer from the filtrate, and washing of the polymer with water. It was also verified by GC analysis of whole cells that had been washed with water and propanolyzed in a mixture of 50% 1,2-dichloroethane, 40% 1-propanol, and 10% concentrated hydrochloric acid at 100° C. for 5 hours, with PHB and sodium 2-hydroxybutyrate as the standards.
EXAMPLE 4
Poly(2HB) from 2-hydroxybutyrate in E. coli
Escherichia coli MBX184 is not capable of synthesizing poly(3-hydroxybutyrate) (PHB) from glucose. MBX184 is deficient in fadR and expresses atoC constitutively.
MBX184 carrying the plasmid pFS30 was precultured at 37° C. in 100 mL of LB medium containing 100 μg/mL sodium ampicillin. The cells were centrifuged at 5000 g for 10 minutes to remove them from the LB medium after 16 hours, and they were resuspended in 100 mL of a medium containing, per liter: 5 g sodium 2-hydroxybutyrate (2HB); 2 g glucose; 2.5 g LB broth powder; 50 mmol potassium phosphate, pH 7; 100 μg/mL sodium ampicillin; and 0.1 mmol IPTG. The cells were incubated in this medium for 3 days with shaking at 150 rpm at 33° C. in the same flask in which they had been precultured.
The cells accumulated a polymer to 1.0% of the dry cell weight that consisted of 100% 2HB units. The identity of the poly(2HB) polymer was verified by GC analysis of whole cells that had been washed with water and propanolyzed in a mixture of 50% 1,2-dichloroethane, 40% 1-propanol, and 10% concentrated hydrochloric acid at 100° C. for 5 hours, with sodium 2-hydroxybutyrate as the standard.
EXAMPLE 5
Poly-3HP and poly-3HP-co-5HV from 1,3-propanediol and from 1,5-pentanediol.
Escherichia coli MBX184 carrying the plasmid pFS30 was precultured at 37° C. in 100 mL of LB medium containing 100 μg/mL sodium ampicillin. The cells were centrifuged at 5000 g for 10 minutes to remove them from the LB medium after 16 hours, and they were resuspended in 100 mL of a medium containing, per liter: 10 g 1,3-propanediol (1,3-PD) or 1,5-pentanediol (1,5-PD); 2 g glucose; 2.5 g LB broth powder; 50 mmol potassium phosphate, pH 7; 100 μg/mL sodium ampicillin; and 0.1 mmol IPTG. The cells were incubated in this medium for 3 days with shaking at 200 rpm at 30° C. in the same flask in which they had been precultured. When the diol substrate was 1,3-PD, the cells accumulated a polymer to 7.0% of the dry cell weight that consisted entirely of 3HP units. When the substrate was 1,5-PD, the cells accumulated a polymer to 22.1 % of the dry cell weight that consisted of greater than 90% 3-hydroxypropionate units and less than 10% 5-hydroxyvalerate units. The identity of the poly(3-hydroxypropionate) polymer was verified by NMR analysis of the solid product obtained by sodium hypochlorite extraction of whole cells followed by centrifugation and washing of the polymer with water. The identity of both polymers was verified by GC analysis of sodium hypochlorite-extracted polymer that was propanolyzed in a mixture of 50% 1,2-dichloroethane, 40% 1-propanol, and 10% concentrated hydrochloric acid at 100° C. for 5 hours, with β-propiolactone and δ-valerolactone as the standards.
EXAMPLE 6
Poly-5HV from 5-hydroxyvaleric acid
Escherichia coli MBX1177 carrying the plasmid pFS30 was precultured at 37° C. in 50 mL of LB medium containing 100 μg/mL sodium ampicillin. The cells were centrifuged at 5000 g for 10 minutes to remove them from the LB medium after 8 hours, and they were resuspended in 100 mL of a medium containing, per liter: 10 g sodium 5-hydroxyvalerate (5HV); 5 g glucose; 2.5 g LB broth powder; 50 mmol potassium phosphate, pH 7; 100 μg/mL sodium ampicillin; and 0.1 mmol IPTG. The sodium 5HV was obtained by saponification of d-valerolactone. The cells were incubated in this medium for 3 days with shaking at 200 rpm at 30° C. in the same flask in which they had been precultured. GC analysis was conducted with lyophilized whole cells that were butanolyzed in a mixture of 90% 1-butanol and 10% concentrated hydrochloric acid at 110° C. for 5 hours; the standard was sodium 5-hydroxyvalerate. This analysis showed that the cells had accumulated poly(5HV) to 13.9% of the dry cell weight. The identity of the poly(5-hydroxyvalerate) polymer was verified by NMR analysis of the solid product obtained by 1,2-dichloroethane extraction of whole cells followed by centrifugation and washing of the polymer with water.
Modifications and variations are intended to come within the scope of the appended claims.
2
1
49
DNA
Artificial Sequence
Description of Artificial Sequence
Primer- orfZ 5′ AvrII
1
tcccctagga ttcaggaggt ttttatggag tgggaagaga tatataaag 49
2
38
DNA
Artificial Sequence
Description of Artificial Sequence
Primer- orfZ 3′ SalI
2
ccttaagtcg acaaattcta aaatctcttt ttaaattc 38
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Several novel PHA polymer compositions produced using biological systems include monomers such as 3-hydroxybutyrate, 3-hydroxypropionate, 2-hydroxybutyrate, 3-hydroxyvalerate, 4-hydroxybutyrate, 4-hydroxyvalerate and 5-hydroxyvalerate. These PHA compositions can readily be extended to incorporate additional monomers including, for example, 3-hydroxyhexanoate, 4-hydroxyhexanoate, 6-hydroxyhexanoate or other longer chain 3-hydroxyacids containing seven or more carbons. This can be accomplished by taking natural PHA producers and mutating through chemical or transposon mutagenesis to delete or inactivate genes encoding undesirable activities. Alternatively, the strains can be genetically engineered to express only those enzymes required for the production of the desired polymer composition. Methods for genetically engineering PHA producing microbes are widely known in the art (Huisman and Madison, 1998, Microbiology and Molecular Biology Reviews, 63: 21-53). These polymers have a variety of uses in medical, industrial and other commercial areas.
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This application is a continuation of application Ser. No. 532,022, filed May 31, 1990 now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to a fuel injection pumping apparatus for supplying fuel to a compression ignition engine and of the kind comprising a low pressure pump which supplies fuel to a high pressure pump, the output pressure of the low pressure pump varying in accordance with the speed at which the apparatus is driven, a fuel pressure operable device for varying the timing of fuel delivery by the high pressure pump and means for controlling the quantity of fuel which is supplied by the high pressure pump.
It is known that the timing of delivery of fuel to a compression ignition engine must be carefully controlled in order to avoid the emission of noxious exhaust gases.
A known apparatus of the aforesaid kind is seen in GB 2174515B, in which fuel from the low pressure pump flows through a first orifice and then through a second orifice with the pressure developed intermediate the orifices being applied to the pressure operable device. Downstream of the second orifice is a variable orifice through which the fuel can flow to a drain and the degree of restriction offered by the variable orifice is arranged to vary in accordance with the amount of fuel delivered by the high pressure pump, the degree of restriction increasing as the quantity of fuel supplied by the high pressure pump is decreased. Arranged in parallel with the aforesaid variable orifice is a bypass valve which has a valve member responsive to the pressure intermediate the first and second orifices and moving with increasing pressure against the action of a spring to progressively open a bypass passage to drain. The extent of movement of the valve member is limited by an adjustable stop to control the maximum effective size of the bypass passage.
The setting of the adjustable stop is critical for the correct functioning of the apparatus and in some instances it has been found to be very difficult to adjust the setting of the stop.
SUMMARY OF THE INVENTION
The object of the present invention is to provide an apparatus of the kind specified in an improved form.
According to the invention an apparatus of the kind specified further comprises a first orifice through which fuel can flow from the outlet of the low pressure pump, a second orifice connected in series with the first orifice, the pressure intermediate said orifices being applied to the pressure operable device, a variable orifice downstream of said second orifice and through which fuel can flow to a drain, the size of said variable orifice depending on the quantity of fuel delivered by the high pressure pump, with the degree of restriction increasing as the quantity of fuel supplied is decreased, a bypass valve connected in parallel with said variable orifice, said bypass valve including a spring loaded valve member slidable within a cylinder, a passage connecting one end of the cylinder to a point intermediate said first and second orifices so that with increasing pressure the valve member is moved against the action of the spring, a port opening into the wall of the cylinder, the port being connected to a point intermediate the second orifice and said variable orifice, a groove on the periphery of the valve member, said groove communicating with said drain, the groove as the valve member is moved against the action of the spring being brought into register with said port, the apparatus being characterised by a further restricted orifice interposed in the connection between said groove and the drain.
BRIEF DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a diagrammatic representation of an example of an apparatus in accordance with the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawing the apparatus comprises a low pressure pump 10 having an outlet 11 which supplies fuel by way of the fuel control means 12 to a high pressure pump 13 the latter having outlets for connection to the injection nozzles of the associated engine. The apparatus may be of the rotary distributor type with the distributor driven in timed relationship with the associated engine and with the rotary part of the low pressure pump connected to the distributor. The outlet pressure of the low pressure pump is controlled by a valve 14 which interconnects the inlet and outlet of the pump.
The fuel control device 12 comprises an angularly adjustable member 15 the angular setting of which in practice is determined by a speed responsive governor. Formed in the member 15 is an axially extending slot 16 which communicates with the outlet 11 of the low pressure pump and can register with a port 17 connected to the inlet of the high pressure pump and formed in the wall of the cylinder in which the member 15 is mounted. As the member is moved angularly so the degree of registration of the slot 16 and port 17 will vary and therefore the amount of fuel which is supplied by the high pressure pump will depend upon the angular setting of the member 15.
The high pressure pump includes a cam which is angularly adjustable to determine the instant at which fuel is delivered through one of the outlets of the high pressure pump and the cam is adjustable by means of a fluid pressure operable piston 18 which is coupled to the cam ring by means of a peg 19. The piston 18 is loaded by a spring 20 in the direction to retard the timing of fuel delivery and fuel under pressure can be applied to the piston to move it against the action of the spring through a passage 21 communicating with the end of the cylinder containing the piston, increasing fuel pressure advancing the timing of fuel delivery to the associated engine.
The apparatus also includes first and second fixed orifices 22, 23, connected in series, with the orifice 22 being located in a passage which is connected to the outlet 11 of the low pressure pump 10. The passage 21 is connected to a point intermediate the orifices 22, 23 by way of a check valve 24 and downstream of the orifice 23 is a variable orifice 25A constituted by a helical groove 25 formed on the wall of the member 15. One end of the groove 25 extends beyond the end of the cylinder into which the member 15 is mounted and communicates with the interior of the housing of the apparatus which can be regarded as being at drain pressure. As the member 15 is moved angularly to vary the quantity of fuel which is supplied to the engine the registration of the groove 25 with a port 26 in the wall of the cylinder in which the member is mounted, varies and it is arranged that the smaller the amount of fuel supplied to the high pressure pump, the greater will be the degree of restriction to the flow of fuel between the port and the groove 25.
Associated with the orifice 22 is a control valve 27 which includes a spring loaded valve member 28 slidable within a cylinder 29. One end of the cylinder is in communication with the outlet 11 of the low pressure pump and the valve member is biased towards this end of the cylinder by means of a coiled compression spring 30. The other end of the cylinder is connected to the downstream side of the orifice 22 and also connected to the downstream side of the orifice 22 is a port 31 opening into the wall of the cylinder 29 intermediate the ends thereof. For registration with the port 31 there is provided on the periphery of the valve member a circumferential groove 32 which is in constant communication with the outlet of the low pressure pump by way of an axial drilling 33 formed in the valve member.
There is also provided a bypass valve 34 and this includes a valve member 35 slidable within a cylinder 36 one end of the cylinder being connected to a point intermediate the orifices 22 and 23. The valve member is biased towards this end of the end of the cylinder by means of a coiled compression spring 37 and opening into the wall of the cylinder is a port 38 which communicates with the downstream side of the orifice 23. The other end of the cylinder is connected to the interior of the housing of the apparatus by way of a restricted orifice 39 and formed in the periphery of the valve member is a circumferential groove 40 which communicates with the aforesaid other end of the cylinder by way of a drilling 41 formed in the valve member. The groove 40 as the valve member moves against the action of its spring, progressively uncovers the port 38.
In operation, and considering firstly that the member 15 is set to allow the maximum flow of fuel to the high pressure pump so that there is a minimum of resistance to fuel flow along the groove 25. At low engine speeds the valve members 28 and 35 of the valves 27 and 34 assume positions at the ends of the respective cylinders and fuel from the low pressure pump flows through the orifices 22 and 23 which are connected in series, from the outlet 11 of the low pressure pump to the interior of the housing. The pressure which is applied to the piston 18 is therefore the outlet pressure of the low pressure pump minus the pressure drop across the orifice 22. As the engine speed continues to increase the output pressure of the low pressure pump will also increase and an increasing pressure will be applied to the piston 18. This pressure is also effective on the valve member 35 and can move this valve member against the action of the spring 37. Such movement however will have no effect upon the pressure applied to the piston since the downstream side of the orifice 23 is already in communication with the interior of the housing through the port 26 and groove 26 and the fact that the port 38 is uncovered is largely immaterial. However, as the output pressure of the low pressure pump increases as the engine speed increases, there will be an increase in the pressure drop across the orifice 22 and eventually the pressure drop will become sufficiently large to cause movement of the valve member 28 against the action of the spring 30. A point will be reached at which the groove 32 is uncovered to the port 31 and the valve 27 then acts as a constant pressure drop valve so that the pressure which is applied to the piston 18 corresponds to the outlet pressure of the low pressure pump minus a constant value determined by the valve 27. The pressure of fuel applied to the piston 18 therefore increases at a rate which is less than the rate of increase of the output pressure of the pump 10 but when the valve 27 becomes operative the pressure increases at the same rate.
Considering now light load operation of the engine with the member 15 at a position such that minimum fuel is supplied to the engine. In this position the groove 25 no longer communicates with the port 26. At low engine speeds the valve members 28, 35 of the two valves will have moved their maximum extent under the action of their springs. Since the port 26 is closed no flow of fuel can take place and therefore at low speeds the pressure which is applied to the piston 18 corresponds to the outlet pressure of the low pressure pump. As the engine speed and therefore the pressure increases the valve member 35 will move against the action of its spring and after a predetermined movement the groove 40 will start to uncover the port 38. When this occurs fuel can start to flow through the orifice 23 and the valve 34 acts to maintain the pressure which is applied to the piston 18 substantially constant. Fuel will also flow through the orifice 39 but the size of this orifice is large as compared with the orifice formed by the groove 40 and port 38, at least in the initial stages of movement of the valve member 35. With continued movement of the valve member 35 the size of the orifice formed by the groove 40 and port 38 becomes comparable with that of the orifice 39 and the valve 34 will no longer act to maintain the fuel pressure acting on the piston 18 substantially constant. As therefore the outlet pressure of the low pressure pump continues to increase the pressure applied to the piston 18 will also increase. The increasing pressure drop across the orifice 22 will eventually cause movement of the valve member 28 to allow the groove 32 to move into register with the port 31. The valve 27 will then act as previously described, as a constant pressure drop valve. The pressure applied to the piston 10 as the engine speed increases is therefore initially the output pressure of the pump 10. When the valve 34 is functioning the pressure remains substantially constant until with increasing engine speed, the valve 34 ceases to function as a constant pressure drop valve. The pressure applied to the piston then increases at the same rate of increase as the pressure developed by the pump 10.
The two extreme positions for the member 15 have been described above and it will be appreciated that when the member 15 is set to cause an intermediate quantity of fuel flow to the associated engine, there will be a degree of registration between the groove 25 and the port 26. In this case therefore there will be a small flow of fuel through the orifice 23 and hence a pressure drop across this orifice. At low engine speeds therefore because of the flow of fuel through the orifice 23, the pressure which will be applied to the piston 18 will be lower than in the case when the member 15 is set to provide the minimum fuel flow to the associated engine.
It will be appreciated that the orifice 39 can be located in the drilling 41 in the valve member 35 with the end of the cylinder 36 which contains the spring connected by way of an unrestricted passage with the interior of the housing.
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A fuel injection pumping apparatus for supplying fuel to a compression ignition engine has a low pressure pump which supplies fuel to a high pressure pump by way of a throttle. The high pressure pump has a piston for varying the timing of delivery of fuel. A first fixed orifice connects the outlet of the low pressure pump to the cylinder containing the piston and a second fixed orifice connects the cylinder with a drain by way of a variable orifice. In parallel with the second fixed orifice is a bypass valve including a valve member responsive to the pressure applied to the piston and which with increasing pressure opens to allow fuel to escape through a further fixed orifice from downstream of the second fixed orifice.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefits of U.S. provisional patent application No. 61/282,629 filed on Mar. 9, 2010, which is herein incorporated by reference.
TECHNICAL FIELD
The present disclosure relates to a reverse osmosis system for maple tree sap.
BACKGROUND
Collecting the sap of maple trees to make maple syrup and other derivative products has been known for centuries by North-American Indians and more recently, it has been eagerly taken over by the colonists and is now a thriving industry in the North East United States and south east of Canada. Like most industry, it has to modernize in order to remain profitable and a number of inventions have automated the process.
That is why, over the years, various systems have been used to improve the production of maple syrup. The most expensive and time consuming part of the process of making maple syrup has to do with the boiling of the sap so as to create the sugary concentrate—the maple syrup.
It has been found that by using reverse osmosis, a more concentrated sap can be produced, which requires less boiling time, thus a saving in energy cost. Reverse osmosis for the purpose of filtering water has been known for decades and by discarding the pure water and keeping the concentrate, an improved process for making maple syrup was born.
However, because of their configuration, common reverse osmosis systems take a fair amount of time to drain, are subject to loss of sap during cleanup, are subject to frost because of the difficulty in completely draining the system of liquid and require great quantities of water to properly wash.
Furthermore, common reverse osmosis systems are also subject to downtime caused by the repair, maintenance and replacement of filter banks.
Accordingly, there is a need for a reverse osmosis system that addresses the above-mentioned problems.
SUMMARY
The present disclosure relates to a maple sap reverse osmosis system comprising:
a feed pressure pump configured for receiving maple tree sap; a filter bank; at least one pressure pump operatively connected to the feed pressure pump through the filter bank; at least one recirculation pump operatively connected to the at least one pressure pump, each recirculation pump having an associated housing having an input positioned at a bottom portion of the housing, a permeate output and a concentrate output, the housing enclosing a membrane producing permeate and concentrate from the maple sap; and an air inlet operatively connected to a housing in a exit position;
wherein the housings are serially connected from an entrance position housing to the exit position housing through associated inputs and concentrate outputs and wherein the housings can be completely drained of liquid through the input of the entrance position housing.
The present disclosure also relates to a maple sap reverse osmosis system comprising:
a feed pressure pump configured for receiving maple tree sap; a filter bank; at least one pressure pump operatively connected to the feed pressure pump through the filter bank; at least one recirculation pump operatively connected to the at least one pressure pump, each recirculation pump having an associated housing having an input, a permeate output and a concentrate output positioned at a bottom portion of the housing, the housing enclosing a membrane producing permeate and concentrate from the maple sap; and an air inlet operatively connected to a housing in an entrance position;
wherein the housings are serially connected from the entrance position housing to an exit position housing through associated inputs and concentrate outputs and wherein the housings can be completely drained of liquid through the concentrate output of the exit position housing.
The present disclosure further relates to a maple sap reverse osmosis system comprising:
a feed pressure pump configured for receiving maple tree sap; a plurality of filter banks; a set of path selectors being configured to provide maple tree sap to selected filter banks; at least one pressure pump operatively connected to the feed pressure pump through the filter banks; at least one recirculation pump operatively connected to the at least one pressure pump, each recirculation pump having an associated housing having an input, a permeate output and a concentrate output, the housing enclosing a membrane producing permeate and concentrate from the maple sap; and an air inlet operatively connected to a housing in an entrance position;
wherein the housings are serially connected from the entrance position housing to an exit position housing through associated inputs and concentrate outputs.
BRIEF DESCRIPTION OF THE FIGURES
Embodiments of the disclosure will be described by way of example only with reference to the accompanying drawing, in which:
FIG. 1 is a schematic representation of the maple sap reverse osmosis system in accordance with a first illustrative embodiment of the present disclosure;
FIG. 2 is a schematic representation of the maple sap reverse osmosis system in accordance with a second illustrative embodiment of the present disclosure;
FIG. 3 is a schematic representation of the maple sap reverse osmosis system in accordance with a third illustrative embodiment of the present disclosure;
FIG. 4 is detailed view of a first example of a membrane sub-system in accordance with an illustrative embodiment of the present disclosure;
FIG. 5 is detailed view of a second example of a membrane sub-system in accordance with an illustrative embodiment of the present disclosure;
FIG. 6 is detailed view of a third example of a membrane sub-system in accordance with an illustrative embodiment of the present disclosure;
FIG. 7 is detailed view of a fourth example of a membrane sub-system in accordance with an illustrative embodiment of the present disclosure;
FIG. 8 is a schematic representation of the maple sap reverse osmosis system of FIG. 2 further showing the storage sub-system; and
FIG. 9 is a schematic representation of the maple sap reverse osmosis system of FIG. 1 or 3 further showing the storage sub-system.
DETAILED DESCRIPTION
Generally stated, the non-limitative illustrative embodiment of the present disclosure provides a reverse osmosis system for maple tree sap with improved concentrate recuperation and draining of washing soap and permeate. In a further illustrative embodiment, the reverse osmosis system for maple tree sap is provided with redundant feed pumps and filter banks.
Although reference is made throughout the present disclosure to a reverse osmosis system using osmosis membranes, it is to be understood that the description equally applies to similar technologies such as, for example, nano-filtration membranes.
Referring to FIG. 1 , there is shown a maple sap reverse osmosis system 100 in accordance with a first illustrative embodiment of the present disclosure. The reverse osmosis system 100 is generally composed of a pumping sub-system 110 , a membrane sub-system 120 and a washing sub-system 130 . A drain valve V 11 allows the redirection of various liquids at the entry of the reverse osmosis system 100 to the drain.
The pumping sub-system 110 includes a feed pump 112 , receiving maple sap from valve v 9 , permeate from valve v 10 or washing fluid from valve v 8 , and a set of pressure pumps 114 . Between the feed pump 112 and pressure pumps 114 are located two banks of filters 116 a and 116 b comprising three filters each, for example 5 micron filters.
In operation, a single filter bank 116 a or 116 b is used, for example filter bank 116 a , while the other filter bank, i.e. filter bank 116 b , is on standby in case of a failure or for maintenance to one or more filter of first filter bank 116 a.
The selection of which filter bank 116 a or 116 b is in use may be done manually or the pumping sub-system 110 may further include controllers, actuators and sensors so as to detect failures in one or more filter and provide automatic switching between the filter banks 116 a and 116 b by selectively activating valves V 13 a and V 13 b . This redundancy of the filter banks 116 a , 116 b limits costly system downtime, for example normal clogging of the filters alone may require maintenance three to four times a day. Furthermore, an alarm or display may inform an operator previous to a complete stop (for example by detecting a psi variation) that one or more filter of a filter bank requires repairs, maintenance or replacement due to, for example, clogging of the filters. This feature is quite useful as it allows an operator to change a filter bank without having to stop the entire system 100 which may require the shutting down of as many as 15 different motors which then have to be restarted again after the filter bank is replaced.
It is to be understood that the number of filter banks, as well as the number of filters per bank, may vary.
The membrane sub-system 120 includes a set of housings 125 , each having therein an osmosis membrane, with associated recirculation pumps 124 and a check-valve air inlet 152 . The housings 125 and their interconnections will be further detailed below.
It is to be understood that the number of housings 125 and recirculation pumps 124 may vary.
The washing sub-system 130 includes a washing tank 132 , a set of redirection valves V 4 , V 5 , V 6 , V 7 and V 8 , and a drainage valve V 12 . The redirection valves V 4 , V 5 , V 6 and V 7 allow the redirection of concentrate 104 and permeate 106 from the membrane sub-system 120 to respective holding tanks (not shown), the redirection of permeate 106 from the permeate holding tank into the washing tank 132 to be mixed with a cleaning agent to form a washing solution and the redirection of the washing solution, through valve V 8 , into the internal components of the membrane sub-system 120 .
Although not shown, it is to be understood that the reverse osmosis system 100 also includes all the electronics and electrical components necessary for its operation. Also, flow meter gauges providing visual indications of the permeate and concentrate may also be included.
Referring to FIG. 2 , there is shown a maple sap reverse osmosis system 100 ′ in accordance with a second illustrative embodiment of the present disclosure. The reverse osmosis system 100 ′ is generally composed of a pumping sub-system 110 ′, a membrane sub-system 120 ′ and a washing sub-system 130 .
In this illustrative embodiment, the pumping sub-system 110 ′ includes two sets of feed pumps and filter banks, a first set comprising feed pump 112 ′ a and filter bank 116 ′ a , and a second set comprising feed pump 112 ′ b and filter bank 116 ′ b . The filter banks 116 ′ a and 116 ′ b comprise four filters each, for example 5 micron filters.
In operation a single set of feed pumps and filters is used, for example feed pump 112 ′ a and filter bank 116 ′ a , while the other set, feed pump 112 ′ b and filter bank 116 ′ b , is on standby in case of a failure or for maintenance to one or more components of the first set, i.e. feed pump and/or filter.
Again, the selection of which set of feed pump and filters may be done manually or the pumping sub-system 110 ′ may also include controllers, actuators and sensors so as to detect failures in one or more component of a feed pump and filter bank set and provide automatic switching to between sets by selectively activating valves V 13 a and V 13 b . This redundancy of the feed pumps 112 ′ a , 112 ′ b and filter banks 116 ′ a , 116 ′ b limits costly system downtime. Furthermore, an alarm or display may inform an operator before a complete halt of the system 100 that one or more feed pump and/or filter of a filter bank requires repairs, maintenance or replacement due to, for example, clogging of the filters.
It is to be understood that the number of sets of feed pumps and filter banks, as well as the number of feed pumps and filters per set, may vary.
The membrane sub-system 120 ′ includes a set of housings 125 , each having therein an osmosis membrane, with associated recirculation pumps 124 , and a pressure regulator 126 with associated compressed air inlet 138 . The housings 125 and their interconnections will be further detailed below.
It is to be understood that the number of housings 125 and recirculation pumps 124 may vary.
In this embodiment, the washing sub-system 130 is as described in FIG. 1 .
It is to be understood that the pumping, membrane and washing sub-systems may be combined in various configurations. For instance, FIG. 3 shows a maple sap reverse osmosis system 100 ″ in accordance with a third illustrative embodiment of the present disclosure in which the pumping sub-system 110 ′ of FIG. 2 is combined with the membrane 120 and washing 130 sub-systems of FIG. 1 . In a further alternative embodiment (not shown), a maple sap reverse osmosis system may combine the membrane sub-system 120 ′ of FIG. 2 with the pumping 110 and washing 130 sub-systems of FIG. 1 .
It is also to be understood that the other alternative embodiments may include one of the described sub-systems with commonly used sub-systems.
Referring now to FIG. 4 , there is shown a first detailed example of a membrane sub-system 120 ′ in accordance with the general configuration of the membrane sub-system 120 ′ of FIG. 2 . In this example, the membrane sub-system 120 ′ is provided with a set of four housings 125 with associated recirculation pumps 124 . Each housing 125 includes therein an osmosis membrane 122 , for example with a capacity of 600 GPH at 500 psi.
The pumping sub-system 110 provides maple sap to the membrane sub-system 120 ′ through conduit 108 which is connected to the input 128 of the bottommost housing 125 at position BA. The intermediary housings 125 , at positions IA, are interconnected by their respective outputs 129 and inputs 128 . The output 129 of the topmost housing 125 , at position TA, provides the concentrate 104 .
It should be noted that the input 128 of each housing 125 is placed at the bottom, which facilitates the draining of the housing 125 . However, the draining valve 137 being located at the lowest point of the system 100 ′, a few inches from the ground, and the concentrate holding tank being usually elevated with respect to the draining valve 137 , complicate the task of recuperating expensive concentrate still in the various housings 125 . Accordingly, the draining may be accomplished by injecting compressed air through the compressed air inlet 138 of the topmost housing 125 (position TA), the remaining maple sap being forced by the compressed air and gravity in a reverse path through the housings 125 outputs 129 and inputs 128 to be recuperated and redirected to the concentrate holding tank using valve 136 . The compressed air inlet 138 may be provided with a pressure regulator 126 to control the air pressure into the housings 125 .
Referring to FIG. 5 , there is shown a second detailed example of a membrane sub-system 120 ′ in accordance with the general configuration of the membrane sub-system 120 ′ of FIG. 2 . In this example, the positioning of the housings 125 inputs 128 and outputs 129 have been inversed, i.e. the input 128 is located on a top portion of the housing 125 while the output 129 is located on a bottom portion of the housing. This allows the use of valves V 1 combined with valve V 7 to recuperate concentrate in the concentrate holding tank or with valve V 6 to redirect liquids to the washing tank for draining (see also FIG. 2 ).
Referring to FIG. 6 , there is shown a third detailed example of a membrane sub-system 120 ′ in accordance with the general configuration of the membrane sub-system 120 ′ of FIG. 2 . In this example, the configuration of the membrane sub-system 120 ′ is similar to that of membrane sub-system 120 ′ of FIG. 4 scaled to include eight housings 125 with associated recirculation pumps 124 . It is to be understood that the number of housings 125 and associated recirculation pumps 124 may vary as required. Furthermore, because the membrane sub-system 120 ′ uses compressed air or vacuum, the various housings need not be stacked and may be disposed in side by side banks, e.g. two banks of four in the illustrated example, by connecting the output 129 of each topmost housing 125 to the input 128 of the bottommost housing 125 of the next bank.
Referring now to FIG. 7 , there is shown a fourth detailed example of a membrane sub-system 120 ′ in accordance with the general configuration of the membrane sub-system 120 ′ of FIG. 2 . In this example, the configuration of the membrane sub-system 120 ′ includes a generally vertical housing 125 with its input 128 placed at a bottom end and the other components placed similarly as with the previously described membrane sub-system 120 ′ (see FIG. 4 ). It is to be understood, however, that the membrane sub-system 120 ′ may comprise a plurality of generally vertical housings 125 .
It should be noted that in the above configurations, an oil-less air compressor should be used with compressed air inlet 138 in order not to contaminate the osmosis membranes 122 within the housings 125 . Alternatively, an air filter eliminating any traces of oil vapor may be used with an oil based compressor.
It is to be understood that although the above alternative configurations have been described with reference to membrane sub-system 120 ′, these also apply to membrane sub-system 120 using a vacuum system instead of compressed air.
With regard to the configuration of the membrane sub-system 120 of FIGS. 1 and 3 , the draining may be accomplished by connecting a vacuum system commonly used by maple grove operators to collect sap from maple trees to conduit 108 . In this configuration, a vacuum regulator 150 is used to protect the osmosis membranes 122 which, typically, required the pressure to remain below 5 psi. Alternatively, a water pump connected to conduit 108 may be used to extract the concentrate still in the housings 125 and to redirect it at the output of the pump to the concentrate holding tank 144 .
Referring now to FIG. 8 , there is shown the connections between the washing sub-unit 130 and the membrane sub-system 120 ′ of FIG. 2 to a tank sub-system 140 comprising a concentrate holding tank 144 , a maple sap holding tank 142 and a permeate holding tank 146 . It should be noted that the pumping sub-system is not shown in this figure.
FIG. 9 shows the connections between the washing sub-unit 130 and the membrane sub-system 120 of FIGS. 1 and 3 to a tank sub-system 140 comprising a concentrate holding tank 144 , a maple sap holding tank 142 and a permeate holding tank 146 . It should be noted that the pumping sub-system is not shown in this figure.
In conventional systems, concentrate is recuperated by injecting permeate into the membrane sub-system in order to push the concentrate out of the housings. This has the disadvantage that of diluting the concentrate (e.g. from 15′brix down to 2′brix) thus adding pure water into the concentrate holding tank. At some point the operator simply redirects the concentrate/permeate mixture to the drain in order to limit the addition of pure water into the concentrate holding tank. This results in concentrate waste. However, the use of compressed air, vacuum or a water pump as provided with the present membrane sub-system 120 , 120 ′ allows for the complete recuperation of the concentrate still present in the housings 125 at the end of each day, e.g. 160 liters at 15′brix, compared to about 800 liters at 4′brix with the conventional method.
Further to the recuperation of concentrate, the present membrane sub-system 120 , 120 ′ also provides for the evacuation of the washing solution from the housings 125 after a cleaning cycle, which accelerates the process and greatly reduces the amount of permeate required for rinsing.
Once the membrane sub-system 120 , 120 ′ has been properly rinsed with permeate and then drained, as described above, the reverse osmosis system 100 , 100 ′, 100 ″ can be restarted easily with a concentrate quickly attaining 15′brix as the housings 125 are free of permeate that affect the concentration of the sap entering the system at startup. This is a great advantage as the evaporation of the concentrate is a costly operation and any added permeate adds greatly to the cost.
A further advantage of the present membrane sub-system 120 , 120 ′ is that the complete draining of all liquid from the individual housings 125 allows the reverse osmosis system 100 , 100 ′, 100 ″ to be located in an unheated location.
It is further to be understood that the feed pump and filter bank set redundant configuration of the pumping sub-system 110 ′ may also be used with reverse osmosis systems other than the above described reverse osmosis systems 100 and 100 ′.
Although the present disclosure has been described by way of particular embodiments and examples thereof, it should be noted that it will be apparent to persons skilled in the art that modifications may be applied to the present particular embodiments without departing from the scope of the present disclosure.
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A maple sap reverse osmosis system that comprises a feed pressure pump configured for receiving maple tree sap, a filter bank, at least one pressure pump operatively connected to the feed pressure pump through the filter bank, at least one recirculation pump operatively connected to the at least one pressure pump, each recirculation pump having an associated housing having an input positioned at a bottom portion of the housing, a permeate output and a concentrate output, the housing enclosing a membrane producing permeate and concentrate from the maple sap and an air inlet operatively connected to a housing in a exit position. The housings are serially connected from an entrance position housing to the exit position housing through associated inputs and concentrate outputs and wherein the housings can be completely drained of liquid through the input of the entrance position housing.
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BACKGROUND OF THE INVENTION
The present invention relates to laser systems and, more particularly, to a novel tunable laser system emitting coherent radiation in the vacuum-ultraviolet and ultraviolet regions of the electromagnetic spectrum, with wavelengths from about 1650 A to about 3300 A.
There is presently considerable interest in laser systems emitting coherent radiation in the vacuum-ultraviolet (VUV) region of the electromagnetic spectrum and particularly in a tunable VUV emitting laser system. Lasers emitting in the visible and infrared regions are well known, as are tunable coherent sources, such as dye lasers and the like, which are limited to the wavelength region from about 4000 A to about 1 micron. Production of coherent radiation at wavelengths considerably shorter than the above-mentioned 4000 A region is particularly desirable, due to the potential for the photon in the 1650 A to 3300 A region reacting strongly with biological tissues, whereby self-coagulating incisions and destruction of malignant tissue at potentially-inoperable sites may be eventually achieved.
BRIEF SUMMARY OF THE INVENTION
In accordance with the invention, a tunable laser system emitting coherent radiation from about 1650 A to about 3300 A comprises a single lattice crystal of a fluoride of at least a column IIIb metal doped with activator ions of at least one of the lanthanide-series elements. The crystal is pumped by a source of energy having an output wavelength in the region of 1600 A and an output power sufficient to achieve a high power density, at the surface of the crystal, on the order of 10 6 watts/cm 2 . The crystal, of a material chosen from a variety of materials each fluorescing over a portion of the total range of output wavelengths, is positioned between a partly transmissive mirror and optical tuning means, such as a rotatable diffraction grating, an etalon, a prism and rotatable fully reflective mirror and the like.
Single frequency VUV wavelength coherent operation is possible solely with the crystal (without an optical system); the coherent radiation being emitted at the peak wavelength of the fluorescence spectrum of the crystal material.
Suitable dopants include cerium, praesodymium, neodymium, erbium and thulium.
Accordingly, it is an object of the present invention to provide a tunable laser system emitting coherent radiation over the spectrum from about 1650 A to about 3300 A.
It is another object of the present invention to provide a non-tunable laser system emitting coherent radiation at a selected one of a plurality of possible wavelengths in the VUV portion of the electromagnetic spectrum, the laser system operating without an optical cavity or additional optical elements.
These and other objects of the present invention will become clear to those skilled in the art upon consideration of the following detailed description and the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of one preferred embodiment of a tunable VUV laser system in accordance with the principles of the present invention;
FIG. 2 is a graph illustrating the intensity-wavelength relationship between the fluorescence spectra of one material usable for the crystal of the tunable laser system of the present invention and of the excitation spectrum therefor;
FIG. 3 is a diagram illustrating alternative pumping means and tuning means for the tunable laser system of FIG. 1; and
FIG. 4 is a schematic illustration of a non-tunable laser system operation in accordance with the principles of the invention and characterized by operation without optical cavity means.
DETAILED DESCRIPTION OF THE INVENTION
Referring initially to FIG. 1, tunable laser system 10 comprises a single lattice crystal 11, of good optical quality, of a material emitting a broad fluorescence output spectrum over at least a portion of the wavelength range between about 1650 A and about 3300 A. Advantageously, crystal 11 is radially encased in heat sink means 12, having high thermal conductivity, to allow transmission of heat from lasing crystal 11 to the ambient environment. Excitation means 14, in one preferred embodiment, comprises pump means 15, such as the molecular hydrogen laser described by Waynant et al. in 17 App. Phys. Letters 383 (1970) and the like, emitting radiation 16 having wavelengths in the region of about 1600 A, and lens means 17 for converging a beam of radiation 18 upon the surface of lasing crystal 11. A molecular hydrogen laser 15 is particularly advantageous in that the pumping power available, on the order of 10 5 watts of pulsed power, may easily be focussed to provide a surface pumping level of about 10 6 watt/cm. 2 , as required for crystal materials more fully set forth hereinbelow. It should be understood that excitation means 14 can emit an electron beam or synchotron radiation, with suitable means being utilized to focus the pumping energy onto crystal 11.
A partially transmissive-partially reflective mirror 19 is positioned with its surfaces essentially parallel to the plane of a first crystal end surface 11a, while a diffraction grating 20 maintained on a holding member 21 which is rotatable about a pivot means 22, positioned along the central optical axis of crystal 11, is positioned spaced from the remaining crystal end surface 11b. Both end surfaces 11a and 11b may be fabricated at the Brewster angle, with respect to the central optical axis of crystal 11, to reduce reflection losses.
We have found that appropriate materials for lasing crystal 11 comprise a group of activated fluorides of at least a column IIIb element, wherein the crystal lattice, which may advantageously be grown by the Czochralski method (in an atmosphere of helium and hydrogen fluoride), includes at least one species of dopant ions of the lanthanide-series elements: cerium, praesodymium, neodymium, erbium and/or thulium. Referring to FIG. 2, the excitation and emission spectra of one particular material of this group, YF 3 :0.1% Nd, is shown. Abscissa 25 is scaled in increasing wavelength in angstroms and ordinate 26 is scaled in arbitrary units of intensity. Excitation 27, illustratively being the approximately 10 lines emitted between about 1567 A and about 1613 A by the pulsed output of the aforementioned electron-beam-excited molecular hydrogen laser, causes the electrons of the particular activator ions (neodymium in the present example) to be pumped to the 5d state, which state is highly unstable. The excited electrons revert to the ground state, releasing energy having wavelengths corresponding to the entire range of difference energies between all positions in the 5d level and the ground state. The crystal fluoresces over a broad band 28 of wavelengths (about 1710 A to about 1850 A) with a measured VUV fluorescent quantum yield of about 0.75±0.1 and a fluorescence life time which we estimate to be about 5 nanoseconds.
Advantageously, heat sink 12 is formed of a material having a high transmissivity to the excitation wavelengths, whereby the focussed rays 18 may pass directly through heat sink 12 to pump lasing crystal 11 for emission of fluorescence spectra 28 thereby. Alternatively, a portion 12a of the heat sink may be removed to allow focussed beams 18 to impinge directly upon the surface of crystal 11 and a portion 12b, opposite portion 12a, may be coated with a reflecting material to concentrate beam 18 in the crystal to obtain the required threshold pumping power to achieve a fluorescence spectrum of suitable amplitude for lasing action.
Energy in the broadband fluorescence emission 28 (FIG. 2) is emitted from both end surfaces 11a and 11b of the crystal. The energy emitted from end surface 11b is incident upon diffraction grating 20, at an incident angular orientation relative to the central optical axis of the crystal, adjusted by rotation of diffraction grating 20 and holding member 21 about its pivot means 22, to cause only one of the wavelengths contained in the broad fluorescence spectrum to be reflected by grating 20 and returned along the central optical axis, as shown by photon beam 29. The remaining wavelengths of the broad fluorescence spectrum are returned from diffraction grating 20 as beams 30, 31 having non-zero angular orientation with respect to the central optical axis. As is well known, these beams diverge and are not amplified by repeated transmission through the fluorescing crystal. The partially amplified beam 29 propagates essentially along the central optical axis to emerge from end surface 11a; a portion of the energy emerging therefrom is transmitted through mirror 19 as a beam 33 of coherent radiation, while substantially all of the remainder of the energy is returned in beam 34 to crystal 11 to undergo continued amplification during the fluorescence lifetime of each lasing pulse. Thus, a pulse of coherent radiation, having a wavelength tunably selected (by action of diffraction grating 20) from the broad fluorescence emission spectrum 28 of the material forming crystal 11, is emitted as a beam 33 from laser system 10. It should be understood that, while the present preferred embodiment is illustrated as being a pulsed output laser system, this is only due to the present unavailability of continuous pumping sources at the desired excitation wavelength of about 1600 A; we believe that continuous-wave emission from laser system 10 is possible if a beam of electrons is used as a pumping source or if a continuous excitation means were to be available.
As seen from FIG. 2, only a small portion 28 of the wavelength range 1650 - 3300 A can be tuned with a crystal 11 of a particular material. Crystals of different materials are utilized to extend the tuning range as required; the corresponding tuning ranges for various compounds are listed in the following table:
______________________________________APPROXIMATE HOST COMPOUND:TUNING RANGE ACTIVATOR DOPANT______________________________________˜1650 A ˜1720 A YF.sub.3 :Er YF.sub.3 :Nd LuF.sub.3 :Er LuF.sub.3 :Tm LiYF.sub.4 :Er LiYF.sub.4 :Tm˜1710 A ˜1850 A YF.sub.3 :Nd LuF.sub.3 :Nd˜1850 A ˜1950 A LaF.sub.3 .Nd LiYF.sub.4 :Nd˜2150 A ˜2600 A LiYF.sub.4 :Pr˜2700 A ˜3300 A YF.sub.3 :Nd+Ce LaF.sub.3 :Nd+Ce LuF.sub.3 :Nd+Ce LiYF.sub.4 :Nd+Ce______________________________________
Crystals of the chosen material for the desired approximate tuning range as grown by known techniques utilizing a phosphor powder of identical chemical composition, prepared as more fully described in our co-pending application Ser. No. 703,094 filed on even data herewith, and incorporated herein by reference. The praesodymium-activated lithium yttrium tetrafluoride, while not described in the aforementioned co-pending application, is formulated as a powder phosphor by identical techniques. It should be understood that other compounds, such as YPO 4 :Pr, Y 2 (SO 4 ) 3 :Pr, BaY 2 F 8 :Pr,BaYF 5 :Pr,KY 3 F 10 :Pr,KYF 4 :Pr and the like, possess the required broadband fluorescence emission spectrum and, if other lanthanide-doped fluorides containing at least a column IIIb element, such as lanthanum, lutetium or yttrium, possess the required broadband fluorescence emission spectrum and, if such materials could be grown as high purity crystals, would be suitable for use in the present invention (the six listed compounds being of the group tunable over the approximate wavelength range of 2250-2600 A). Similarly, while the aforementioned co-pending application does not discuss preparation of the co-doped (neodymium and cerium) materials for the crystals tunable over the approximate wavelength range of 2700-3300 A, preparation of the co-doped powder phosphors of the four listed host materials is disclosed therein and preparation of the initial phosphor materials for growth of the lasing crystal proceed along identical steps. The 2700-3300 A broadband fluorescence spectrum in this last group of materials is attributable to the cerium activator ions, with neodymium ions being present to absorb the VUV excitation energy and facilitate transfer thereof to the cerium ions which then fluoresce in the desired emission range.
Referring now to FIG. 3, wherein like reference designations are utilized for like elements, several variations in the preferred tunable laser system of FIG. 1 include the use of a cylindrical jacket 40, concentrically formed about lasing crystal 11, containing xenon or other gases capable of being pulse-formed into a plasma responsive to the receipt of pumping energy 41 from a laser pump means 42 (such as the CO 2 laser described by Silfvast et al in 25 App. Phy. Ltrs. 274 (1975)) to supply the pumping energy to crystal 11. As mentioned hereinabove, the pivotable diffraction grating 20 may be replaced by etalons or by the illustrated fixed prism 44 and fully-reflective mirror 45 selectively rotatable in either radial direction, indicated by arrows A and B, about the center of prism 44. In operation, the fluorescence output of lasing crystal 11 travels along a central optical axis thereof to prism 44 which acts as a wave analyzer imparting different angular rotations (relative to the central optical axis) to photons of differing wavelength, whereby at a selected position of mirror 45, only that beam 47 of a single selected wavelength is returned, via prism 44, to lasing crystal 11 for amplification and emission as coherent beam 33. Other wavelengths, illustratively forming beams 48a and 49a, impinge upon mirror 45, at angles deviating from the normal to the surface of the mirror, and are reflected as beams 48b and 49b, respectively diverging from a central optical axis whereby further amplification and emission of these wavelengths is prevented.
Referring to FIG. 4, a source of coherent radiation, at a single wavelength equal to the peak wavelength of the phosphor material from which crystal 11 is formed, comprises the crystal 11 operating in a superradient mode as net gain per pass (through the crystal) is greater than one, and its excitation means 14. Thus, optical cavities (as formed by mirror 19 and one of pivotable diffraction grating 20, prism 44-rotatable mirror 45, etalons, or the like) are not required; however, while coherent radiation 50, emitted from both end surfaces 11a and 11b, is produced by use of a material listed in the table (and particularly at VUV wavelengths, i.e., less than about 2000 A, using specific ones of the first 10 materials of the above table), tuning is not possible and the frequency will be that of the peak of the fluorescence emission of the particular host material-activator dopant compound.
While the novel tunable laser system of the present invention has been described with reference to several preferred embodiments thereof, many other variations and modifications will now become apparent to those skilled in the art. It is our intent, therefore, to be limited not by the foregoing disclosure of these preferred embodiments, but only by the appended claims.
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A tunable laser system emitting coherent radiation selectively variable over the range of wavelengths from about 1650 A to about 3300 A utilizes a crystal, composed of a fluoride of at least a Column IIIb metal doped with at least one trivalent ion of a lanthanide series element, and pumped with high average power pulses. The crystal is emplaced in an optical cavity having means, such as a diffraction grating, etalon, or optically-tunable prism, to vary the coherent emission wavelength.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a non-provisional application of U.S. Provisional Application No. 61/745,426, Attorney Docket No. 358, filed on Dec. 21, 2012, which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates generally to medical devices, and more particularly to endo-cutters or micro-cutters and stapling systems for performing various surgical procedures.
BACKGROUND
[0003] Traditionally, surgeons use sutures to close wounds and incisions, attach separate tissue structures to one another, and perform other medical or surgical functions during various surgical procedures or operations. However, proper suturing requires significant skills to perform; in particular, complex suturing procedures can be time-consuming and/or very difficult to perform effectively. Furthermore, suturing may be impractical or unfeasible in certain situations. For example, suturing may be very difficult to perform in minimally-invasive surgical procedures where suturing tools may be required to be inserted through a small opening (often referred to as an access port) to gain access into a patient's body, and then the suturing operation is performed through the small access opening with extension tools to suture the target tissue. In such minimally-invasive surgical procedures, the opening or access port to the surgical site inside the patient may not be large enough to allow effective maneuvering of suturing tools to perform the suturing procedure efficiently and effectively. If access ports were made larger to allow for easier suturing operations, the benefits of minimally-invasive surgery, however, may be significantly reduced or altogether eliminated. Indeed, as surgical technology continues to progress, the size of the access ports required to access surgical sites in the body to perform minimally-invasive procedures correspondingly continues to decrease. Presently, micro-laparoscopy typically utilizes instruments with diameter of about 2 millimeters to about 3 millimeters to perform complex operations; e.g., laparoscopic cholecystectomy and inguinal hernia repair. When instruments of such small diameters are used, the size of the access ports can also be very small. It is common that the access ports can be as small as about 2 millimeters to about 3 millimeters in diameters. The benefits of these advances in surgical technology to the patients are obvious, minimally-invasive procedures can cause less physical trauma to the patient. As such, these minimally-invasive procedures can be performed to greater percentage of patients even if they are not in the best physical condition. In addition, because there is generally less physical trauma involved, the patients may experience less discomfort, the recovery time is typically reduced, and there may be less scarring at the operation site. However, because of restricted access, it can be significantly difficult or even impossible sometimes to perform effective suturing within a patient's body through these small access ports in minimally-invasive procedures. As such, alternatives to suturing are highly desired.
SUMMARY
[0004] The present disclosure relates generally to medical devices, and more particularly to endo-cutters or micro-cutters and stapling systems for various surgical procedures. As disclosed, a surgical stapling apparatus is configured to perform stapling and/or cutting operations on a target tissue of a patient. The surgical stapling apparatus comprises of a mode selection switch mechanism to place the apparatus in either a clamping operational phase or a deployment operational phase. In the clamping operational phase, various clamp components are operated to facilitate loading of surgical staples into the stapling apparatus, if staples are not preloaded, placement of the stapling apparatus to a target surgical site, and clamping of target tissue to be stapled and/or cut. In the deployment operational phase, various deployment components are operated to staple and/or cut the target tissue to one or more desired distance intervals to achieve the desired surgical outcome for the patient.
[0005] To describe some of the operational details, for example, the surgical stapling apparatus includes a clamp spool member that is coupled to a jaw or stapling assembly (e.g., through a clamp strip, etc.) to execute various clamping operations to prepare the surgical stapling apparatus for deployment (e.g., stapling and/or cutting of target tissue of a patient). The clamping operations include placing the jaw or stapling assembly into various clamping modes. A clamp slide member is coupled to the clamp spool member to drive or move the clamp spool member for various clamping operations. The surgical stapling apparatus also includes deployment spool member to operate or drive various components (e.g., a wedge element to deploy staples, a knife element to cut tissue, etc.) to execute various deployment operations (e.g., deployment of staples, cutting of tissue, etc.). A deployment slide member is coupled to the deployment spool member to drive or move the deployment spool member to execute various deployment operations.
[0006] A mode switch mechanism or a mode switch member selectively places the surgical stapling apparatus in either a clamping operational phase or a deployment operational phase.
[0007] Operation of a trigger mechanism or a trigger member operates the mode switch mechanism or the mode switch member to selectively place the surgical stapling apparatus in either the clamping operational phase or the deployment operational phase.
[0008] When in the clamping operational phase, operation of the trigger member operates the components to execute the various clamping functions. The various clamping functions include placing the surgical stapling apparatus and/or the stapling assembly in a first mode or a trocar mode, a second mode or an open mode, a third mode or a clamping mode, etc.
[0009] When in the deployment operational phase, operation of the trigger member operates the components to execute various deployment functions. The various deployment functions include stapling certain amount of target tissue or stapling a target tissue for a certain distance interval. In addition, the various deployment functions include cutting certain amount of target tissue or cutting a target tissue for a certain distance interval.
[0010] The surgical stapling apparatus also includes a clamp lock member configured to place or lock the surgical stapling apparatus in various clamping modes. For example, the surgical stapling apparatus includes a clamp slide pin member coupled to the clamp slide member configured to engage with a clamp lock member to place or lock the surgical stapling apparatus in various clamping modes. The clamp lock member includes a first feature to engage with the clamp slide pin member to place or lock the surgical stapling apparatus in a first mode or a trocar mode. The clamp lock member includes a second feature to engage with the clamp slide pin member to place or lock the surgical stapling apparatus in a second mode or an open mode. The clamp lock member includes a third feature to engage with the clamp slide pin member to place or lock the surgical stapling apparatus in a third mode or a clamping mode.
[0011] The surgical stapling apparatus also includes a clamp lock release member coupled to the clamp lock member that operates to adjust an angular position or orientation of the clamp lock member to allow release of the clamp slide pin member in a locked position to disengage from one of various clamping modes.
[0012] As described from above, the surgical stapling apparatus is configured to perform surgical treatments to a target tissue by operating a trigger member of the surgical stapling apparatus to activate a clamp gear combination, asserting a first trigger-force to place a stapling member in a first mode or trocar mode, asserting a second trigger-force to place the stapling member in a second mode or an open mode, asserting a third trigger-force to place the stapling member in a third mode or a clamp mode, activating a mode selection switch to select a deployment phase; and asserting one or more deployment forces to execute one or more deployment operations. Additionally, asserting a release force to a clamp release member to change an orientation of a clamp lock member to release the stapling member in the first mode or trocar mode, the second mode or open mode or the third mode or clamp mode.
[0013] Furthermore, the surgical stapling apparatus is configured to perform surgical treatments to a target tissue by operating a trigger member of the surgical stapling apparatus to activate a clamp gear combination, asserting a first trigger-force to drive a clamp spool member and a clamp slide member combination to place a stapling member in a first mode or trocar mode, asserting a second trigger-force to drive a clamp spool member and a clamp slide member combination to place the stapling member in a second mode or an open mode, asserting a third trigger-force to drive a clamp spool member and a clamp slide member combination to place the stapling member in a third mode or a clamp mode, activating a mode selection switch to select a deployment phase; and asserting one or more deployment forces to drive a deployment spool member and a deployment slide member combination to execute one or more deployment operations. Additionally, asserting a release force to a clamp release member to change an orientation of a clamp lock member to release the stapling member in the first mode or trocar mode, the second mode or open mode or the third mode or clamp mode. The act of changing the orientation or position of the clamp lock member allows a clamp slide pin to disengage from an engaging feature of the clamp lock member.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The present invention will be readily understood by the following detailed description, taken in conjunction with accompanying drawings, illustrating by way of examples of the invention. The objects and elements in the drawings are not necessarily drawn to scale, proportion, precise orientation or positional relationships; instead, emphasis is focused on illustrating the principles of the invention. The drawings illustrate the design and utility of various features, aspects, or embodiments of the present invention, in which like element are referred to by like reference symbols or numerals. The drawings, however, depict the features, aspects, or embodiments of the invention, and should not be taken as limiting its scope. With this understanding, the features, aspects, or embodiments of the invention will be described and explained with specificity and details through the use of the accompanying drawings in which:
[0015] FIG. 1 illustrates examples of endo-cutter or micro-cutter and stapling systems where the clamp and deploy mechanisms in accordance with features, aspects, or embodiments of the present invention may be used to clamp, cut and staple tissue at surgical sites of a patient.
[0016] FIG. 2A through FIG. 2C illustrates an exposed view of the body, handle, and trigger of an endo-cutter or micro-cutter and stapling system where the clamp and deploy mechanisms are illustrated.
[0017] FIG. 3 illustrates the clamp mechanism components without the body and handle of the endo-cutter or micro-cutter and stapling system in accordance with features, aspects, or embodiments of the present invention.
[0018] FIG. 4 illustrates additional clamp mechanism components without the body and handle of the endo-cutter or micro-cutter and stapling system in accordance with features, aspects, or embodiments of the present invention.
[0019] FIG. 5 illustrates further additional clamp mechanism components without the body and handle of the endo-cutter or micro-cutter and stapling system in accordance with features, aspects, or embodiments of the present invention.
[0020] FIG. 6 illustrates the clamp mechanism in a first mode; for example, trocar mode in accordance with features, aspects, or embodiments of the present invention.
[0021] FIG. 7 illustrates the clamp mechanism in a second mode; for example, open mode in accordance with features, aspects, or embodiments of the present invention.
[0022] FIG. 8 illustrates the clamp mechanism in a third mode; for example, clamping mode in accordance with features, aspects, or embodiments of the present invention.
[0023] FIG. 9A and FIG. 9B illustrate a back view of the endo-cutter or micro-cutter and stapling system where a mode switch mechanism is illustrated in accordance with features, aspects, or embodiments of the present invention.
[0024] FIG. 10 illustrates the deploy mechanism components without the body and handle of the endo-cutter or micro-cutter and stapling system in accordance with features, aspects, or embodiments of the present invention.
[0025] FIG. 11 illustrates illustrate a back view of the endo-cutter or micro-cutter and stapling system where a mode switch mechanism has been activated to place the endo-cutter or micro-cutter and stapling system in a deployment mode in accordance with features, aspects, or embodiments of the present invention.
[0026] FIG. 12A and FIG. 12B illustrate the deployment mechanism of the endo-cutter or micro-cutter and stapling system in a deployment mode; for example, in a condition ready to deploy an endo-cutter or micro-cutter in accordance with features, aspects, or embodiments of the present invention.
[0027] FIG. 13A and FIG. 13B illustrate the deployment mechanism of the endo-cutter or micro-cutter and stapling system in a first deployed mode; for example, a first trigger-squeeze in the deployment mode.
[0028] FIG. 14A and FIG. 14B illustrate the deployment mechanism of the endo-cutter or micro-cutter and stapling system in a second deployed mode; for example, a trigger-release state after the first deployed mode.
[0029] FIG. 15A and FIG. 15B illustrate the deployment mechanism of the endo-cutter or micro-cutter and stapling system in a third deployed mode; for example, a second trigger-squeeze after the second deployed mode.
[0030] FIG. 16A and FIG. 16B illustrate the deployment mechanism of the endo-cutter or micro-cutter and stapling system in a fourth deployed mode; for example, a trigger-release state after the third deployed mode.
[0031] FIG. 17A and FIG. 17B illustrate a back-view of the endo-cutter or micro-cutter and stapling system illustrating that the mode switch mechanism has been reset to place the endo-cutter or micro-cutter and stapling system in the first mode or trocar mode in accordance with features, aspects, or embodiments of the present invention.
[0032] FIG. 17C and FIG. 17D illustrate a side-view of the endo-cutter or micro-cutter and stapling system illustrating that the mode switch mechanism has been reset to place the endo-cutter or micro-cutter and stapling system in the first mode or trocar mode in accordance with features, aspects, or embodiments of the present invention
[0033] FIG. 18A and FIG. 18B illustrate the deploy mechanism components in a deployed state illustrating that components or accessories (e.g., endo-cutter or micro-cutter) attached or coupled to the deploying components have been deployed or advanced to their deployed state.
DETAILED DESCRIPTION
[0034] FIG. 1 illustrates examples of endo-cutter or micro-cutter and stapling systems 100 that can be alternatives or replacements to suturing. In particular, these endo-cutter or micro-cutter and stapling systems 100 are especially useful as alternatives or replacements to suturing in minimally-invasive surgical procedures. As illustrated in the figure, the operation of cutting and stapling is performed through a long slim shaft 104 . The actual operations of clamping, cutting, and stapling of tissue are performed at the distal-end 106 of the shaft 104 , and the control operations of these procedures are performed at the handle assembly 102 . The distal-end 106 may include a stapling system comprising of a staple channel and a staple anvil, which are illustrated in FIG. 1 . The staple channel may include a staple holder or a staple cartridge for holding staples. The staple anvil deforms the staples as they are deployed. As the staples are deployed, the staples pierce the target tissue and the staple anvil deforms the staples to secure the staples against the target tissue. Further illustrated, the shaft at the distal-end may be substantially flexible and may be articulated. For example, near the distal-end of the shaft may include an articulated section 108 . Various versions of the endo-cutter or micro-cutter stapling systems may have non-articulated rigid shafts, while other versions may include substantially flexible or flexible portions that can be articulated. These and other features allow such examples of endo-cutter or micro-cutter and stapling systems (e.g., MICROCUTTER XPRESS™ and MICROCUTTER XCHANGE™, which are designed and manufactured by Cardica Inc. of U.S.A.) to be ideally suited as alternatives or replacements to suturing. Greater detailed discussions of endo-cutter or micro-cutter stapling systems are described in U.S. patent application Ser. No. 12/323,309, Attorney Docket No. 248, filed on Nov. 25, 2008; U.S. patent application Ser. No. 12/400,760, Attorney Docket No. 252, filed on Mar. 9, 2009; U.S. patent application Ser. No. 12/400,790, Attorney Docket No. 257, filed on Mar. 9, 2009; U.S. patent application Ser. No. 12/477,065, Attorney Docket No. 275, filed on Jun. 2, 2009; U.S. patent application Ser. No. 12/787,708, Attorney Docket No. 308, filed on May 26, 2010; U.S. patent application Ser. No. 13/093,791, Attorney Docket No. 328, filed on Apr. 25, 2011; U.S. patent application Ser. No. 12/477,302, Attorney Docket No. 276, filed on Jun. 3, 2009; U.S. patent application Ser. No. 12/489,397, Attorney Docket No. 283, filed on Jun. 22, 2009; U.S. patent application Ser. No. 12/612,614, Attorney Docket No. 284, filed on Nov. 4, 2009; U.S. patent application Ser. No. 12/840,156, Attorney Docket No. 310, filed on Jun. 20, 2010; U.S. patent application Ser. No. 13/028,148, Attorney Docket No. 319, filed on Feb. 15, 2011; U.S. patent application Ser. No. 13/048,674, Attorney Docket No. 322, filed on Mar. 15, 2011; U.S. patent application Ser. No. 13/094,716, Attorney Docket No. 324, filed on Apr. 26, 2011; U.S. patent application Ser. No. 13/094,805, Attorney Docket No. 326, filed on Apr. 26, 2011; U.S. patent application Ser. No. 13/093,743, Attorney Docket No. 327, filed on Apr. 25, 2011; U.S. patent application Ser. No. 13/105,799, Attorney Docket No. 330, filed on May 11, 2011; and U.S. patent application Ser. No. 13/294,160, Attorney Docket No. 340, filed on Nov. 10, 2011, all of which are incorporated herein by reference.
[0035] FIG. 2A through FIG. 2C illustrate exposed and exploded views of the body, handle, and trigger elements of one example of endo-cutter or micro-cutter and stapling system 100 handle assembly 102 where the clamp and deployment mechanisms (e.g., 310 and 1010 in FIG. 2A ) are illustrated. In addition, some of the piece-part components of the handle assembly 102 are separately marked with reference numerals for ease of illustration and discussion, as pertain to and illustrated in FIG. 2B and FIG. 2C . For ease of discussion and additional reference, component or parts identification to the referenced numerals associated with FIG. 2B are: (1)—Release; (2)—Pin (Release); (3)—Spring (Mode Button); (4)—Pin (Release Spring); (5)—Handle (Right); (6)—Handle (Left); (7)—Pin (Clamp Lock); (8)—Pin (Clamp Slide); (9)—Spring (Trigger); (10)—Spring (Release); (11)—Clamp Lock; (12)—Clamp Lock Tab; (13)—Deployment Pulley; (14)—Pin (Deployment Pulley); (15)—Pin (Gear); (16)—Slide (Clamp); (17)—Slide (Deployment); (18)—Washer (Gear); (19)—Clamp Pulley & Gear; (20)—Deploy Pulley & Gear; (21)—Cable Deploy; (22)—Cable Clamp; (23)—Trigger Subassembly; (24)—Adhesive; and (25)—Grease. For ease of discussion and additional reference, component or parts identification to the referenced numerals associated with FIG. 2C are: (1)—Mode Button; (2)—Spring (Ratchet); (3)—Ratchet; (4)—Spring (Trigger Clamp Gear); (5)—Trigger Gear (Deploy); (6)—Trigger Gear (Clamp); (7)—Spring (Trigger Deploy Gear); (8)—Trigger (Left); (9)—Trigger (Right); and (10)—Adhesive.
[0036] As can be depicted from the FIG. 2A , FIG. 2B , and FIG. 2C , the system includes a trigger 302 in the handle assembly 102 to activate the gear system 300 (as indicated in FIG. 3A ) that in turn operate either the clamp or deploy mechanisms (e.g., 310 , 1010 ), depending on which operational mode is selected by a mode switch mechanism 910 , 912 (as illustrated in FIG. 9A , FIG. 9B , and FIG. 11 ).
[0037] FIG. 3 , FIG. 4 , and FIG. 5 illustrate the clamp mechanism components 310 without the body and handle cover of the endo-cutter or micro-cutter and stapling system 100 for ease of illustration and discussion. As can be appreciated from the figures, the trigger member 302 activates a set of clamp gears 300 which in turn pulls on a clamp cable member 322 that asserts a pull force onto a clamp slide member 332 and clamp spool member 342 combination. To be discussed in further detail, as the clamp slide member 332 and clamp spool member 342 combination is either pulled back by the clamp cable member as may be appreciated from the illustration of FIG. 3 or pushed forward by a spring member 412 as illustrated in FIG. 4 , the position of the slide member 332 and spool member 342 combination may be locked into various clamping mode positions (e.g., first mode, second mode, or third mode) by the clamp lock member 512 as illustrated in FIG. 5 . The slide member 332 and spool member 342 can be locked in various positions as a clamp slide-pin member 522 travels either backward (as pulled by the cable member 322 ) or forward (as pushed by the spring member 412 ) along the clamp lock member 512 . The clamp slide-pin 522 may rest on the clamp lock member 512 or in the various notches or detents (e.g., 513 , 523 , etc.) that are on the clamp lock member 512 . The combination of the slide member 332 , spool member 342 , and clamp slide-pin member 522 are configured to operate in concert to hold the jaws (e.g., the staple channel and staple anvil) of the stapling member 106 in various operational modes or positions—such as, a first mode or trocar mode, a second mode or open mode, or a third mode or clamping mode (the stapling member of the distal-end 106 is illustrated in FIG. 1 ).
[0038] As illustrated in FIG. 5 , the clamp slide-pin member 522 is resting near the tip of the clamp lock member 512 (e.g., in a first mode or trocar mode), not in any one of the notches or detents (e.g., 513 , 523 ). These various clamp modes (e.g., first mode or trocar mode, second mode or open mode, or third mode or clamping mode, etc.) are associated with various clamp operational modes of the clamp member 106 or stapling member 106 located at substantially the distal portion of the long slim shaft 104 of the endo-cutter or micro-cutter and stapling system 100 as illustrated in FIG. 1 .
[0039] Typically, in a first state or neutral state, the clamp mechanism components 310 set the clamp or stapling member 106 in a first mode or trocar mode. In this mode, the jaws of the clamp member 106 of the cutter and staple system 100 may be in a smallest or most compact configuration, which allows it to be inserted through a small opening or access port for executing cutting and stapling procedures in minimally invasive surgical operations. As mentioned previously, for example, the clamp 106 may be comprised of stapling jaw components including a staple channel (with a staple holder or staple cartridge) and a staple anvil. As can be observed in FIG. 6 , the slide member 332 is substantially at its most extended position and the clamp slide-pin member 522 is positioned or resting at substantially the tip of the clamp lock member 512 . Also, the trigger member 302 is in its released-state or extended-state, ready to be use—such as ready to be squeezed or activated by a surgeon.
[0040] The clamp mechanism components 310 are activated by a partial-squeeze of the trigger member 302 , as illustrated in FIG. 7 . The partial-squeeze of the trigger member 302 activates the clamp gears 300 to rotate and asserts a pull force onto the slide member 332 to slide backwards toward the proximal portion of the cutter and stapling system 100 . As illustrated in FIG. 7 , the slide member 332 has been pulled back and the clamp slide-pin member 522 is resting in a first notch or first detent 513 on the clamp lock member 512 . The backward movement of the slide member 332 asserts a pull force on the components of the jaws of the clamp (e.g., stapling members: staple channel and staple anvil—not shown) which causes the jaws of the clamp to open in this second mode or open mode. In this second mode or open mode, staples or staple cartridges can be loaded into the clamp or stapling system (e.g., staple channel & staple cartridge combination). Also, after the cutting and stapling system is inserted into the target operational site, in the second mode or open mode, the clamp ( 106 ) can be positioned to grasp tissue for stapling. Further illustrated in FIG. 7 is that a clamp pin-release member or clamp lock release member 524 is in a second-level position in a substantially triangular slot 533 or the first slot 533 , on the clamp lock member 512 , as compared to a first-level position, when the clamp mechanism components 310 are in a first mode or trocar mode as illustrated in FIG. 6 . The clamp pin-release member 524 in a second-level position may cause the clamp lock member 512 to be in a substantially angular orientation as compared to the clamp release-pin 524 in a first-level position. Alternatively, the clamp pin-release member 524 in a second-level position may cause the clamp lock member 512 to be in a substantially greater angular orientation as compared to the pin-release member 524 in the first-level position. When the clamp release-pin 524 is in the first-level position, the clamp lock member 512 may be oriented in a substantially horizontal orientation. Whereas, when the clamp release-pin 524 is in the second-level position, the clamp lock member 512 may be oriented in a slightly or substantially angular orientation or in a substantially non-horizontal orientation.
[0041] FIG. 8 illustrates the clamp mechanism 310 components in a third mode or clamping mode as caused by a full-squeeze or full-activation of the trigger member 302 . The full-squeeze of the trigger member 302 further advances the clamp gears 300 that winds up the cable member 322 , which further pulls the slide member 332 and spool member 342 combination backwards further towards the proximal portion of the cutter and stapling system 100 . The backward movement of the slide member 332 causes the clamp slid-pin member 522 to travel into a second notch or second detent 523 of the clamp lock member 512 . In this mode, the spool member 342 which connects or couples to the components of the jaws of the clamp 106 (e.g., stapling members) causes the jaws of the stapling members 106 to clamp onto the tissue that is ready to be stapled. In this position, in the second notch or second detent 523 , the jaws are secured or locked in clamping mode. Further illustrated in FIG. 8 , the pin-release member 524 is in a third-level position. In this third-level position, the clamp lock member 512 is at a substantial angular orientation, in which the clamp lock member has pivoted about a clamp pin-lock member 702 in a third notch or third detent 543 . In this position, the clamp lock member 512 securely holds the clamp slide-pin 522 in the second notch or second detent 523 of the clamp lock member 512 . To release the jaws of the clamp or the stapling member 106 , the clamp lock member 512 can be moved to “unlock” or “release” the clamp slide-pin member 522 from the second notch or second detent 523 by adjusting or pushing forward the pin-release member or clamp lock release member 524 in the triangular slot 533 . The releasing adjustment or movement of the pin-release member 525 causes the clamp lock member 512 to move or position itself in a substantially “opposite” angular orientation, which allows the clamp slide-pin member to be released from the second notch 523 as the spring member 412 pushes the clamp spool member 342 and clamp slide member 332 forward. Similarly, the clamp slide-pin member 522 can be released from the first notch 513 in a substantially similar manner.
[0042] With the clamp mechanism 310 is in the third mode and target tissue is clamped, the next phase of the operation is ready to be deployed. FIG. 9A and FIG. 9B illustrate a backside view of an endo-cutter or micro-cutter and stapling system 100 where a mode switch mechanism 910 and a mode selection member 912 are illustrated. A stand-off member 902 is shown to engage the clamp gears 300 that drive the clamp mechanism 310 .
[0043] FIG. 10 illustrates the deploy mechanism components 1010 that are used to deploy or drive an endo-cutter or micro-cutter 100 to cut target tissue. Cutting and stapling of target issue may occur at substantially the same time or the operations may be separated by a substantially small time incremental period. As illustrated in FIG. 10 , the deploy mechanism 1010 comprises of a set of deploy gears 1030 , a deployment cable member 1022 , a combination of deployment slide member 1032 and a deployment spool member 1042 , and a deploy pulley member 1052 . FIG. 11 illustrates a backside-view of an endo-cutter or micro-cutter and stapling system where a mode switch mechanism 910 has been activated to place the endo-cutter or micro-cutter and stapling system 100 in a deployment mode. For example, a mode switch button 912 has been pushed or activated to move the stand-off member 902 of the mode switch mechanism 910 to engage the gears 1030 of the deploy mechanism 1010 , while disengaging with the clamp drive gears 300 of clamp mechanism 310 . Once the deploy mechanism 1010 is engaged, activation of the trigger member 302 activates the gears 1030 of the deploy mechanism 1010 which advances or drives the endo-cutter or micro-cutter 100 to cut target tissue. Additionally, the deployment mechanism 1010 may also advances or drives the endo-cutter or micro-cutter 100 to staple target tissue.
[0044] FIG. 12A and FIG. 12B illustrate the deployment mechanism components of the endo-cutter or micro-cutter and stapling system in a deployment mode; for example, in a condition ready to deploy an endo-cutter or micro-cutter. As illustrated in FIG. 12B , a deploy ratchet member 1212 engages a first tooth 1242 of a first deploy gear 1214 . FIG. 13A and FIG. 13B illustrate the deployment mechanism components of the endo-cutter or micro-cutter and stapling system in a first deployed mode; for example, a first trigger-squeeze in the deployment mode. As the trigger member 302 is squeezed or activated, the deploy ratchet member 1212 urges or advances the first deploy gear 1214 , as illustrated in FIG. 13B . The first deploy gear 1214 acts on a second deploy gear 1216 which winds and pulls on a deploy cable member 1222 . The deploy cable member 1222 pulls on the combination of deploy slide member 1032 and deploy spool member 1042 to advance the combination to a first deployed position, illustrated in FIG. 13A . The movement of the combination advances the components associated with the endo-cutter or micro-cutter (such as a deployment strip member 1252 , a knife member (not shown), etc.) to a first position; cutting targeted tissue to a certain distance or interval. Additional deployment members may also be activated, such as a wedge member (not shown) to drive and deploy staples in the clamp member 106 to correspondingly staple the targeted tissue to a certain distance or interval.
[0045] FIG. 14A and FIG. 14B illustrate the deployment mechanism components of the endo-cutter or micro-cutter and stapling system in a second deployed mode; for example, a trigger-release state after the first deployed mode. In FIG. 14A , it is illustrated that the trigger member 302 is released, which causes the deploy ratchet member to return or retreat and engages the second tooth 1244 of the first deploy gear 1214 . In this position, the deploy mechanism 1010 is ready for further deployment.
[0046] FIG. 15A and FIG. 15B illustrate the deployment mechanism components of the endo-cutter or micro-cutter and stapling system in a third deployed mode; for example, a second trigger-squeeze after the second deployed mode. As illustrated in FIG. 15A , the trigger member 302 is squeezed to advance the first deploy gear 1214 , which is illustrated in FIG. 15B . The advancement or rotation of the first deploy gear advances or rotates the second deploy gear 1216 in an opposite direction, which winds or pulls on the deploy cable member 1222 . The deploy cable member 1222 winds around a deploy pulley 1052 and pulls the combination of deploy slide member 1032 and deploy spool member 1042 . The deployment member combination ( 1032 and 1042 ) is moved forward or advanced to a second deployed position, as illustrated in FIG. 15A . The movement of the deployment member combination ( 1032 and 1042 ) advances or drives the components associated with the endo-cutter or micro-cutter further forward (e.g., a deployment strip member 1252 , a knife member (not shown), etc.), thus further cutting the targeted tissue. Additional deployment members may also be activated, such as a wedge member (not shown) to drive and deploy staples in the clamp member 106 to correspondingly staple the targeted tissue to a certain distance or interval.
[0047] FIG. 16A and FIG. 16B illustrate the deployment mechanism components of the endo-cutter or micro-cutter and stapling system in a fourth deployed mode; for example, a trigger-release state after the third deployed mode. As illustrated in FIG. 16A , the trigger member 302 is released, which allows the deploy ratchet member 1212 to return or retreat. The return of the deploy ratchet member 1212 allows it to engage a third tooth 1246 on the first deploy gear 1214 . The engagement of the deploy ratchet 1212 with the third tooth 1246 on the first deploy gear 1214 may provide sufficient adjustments to the engagement of the mode switch mechanism 910 to allow it to reset. For example, the adjustment may allow the mode switch mechanism 910 and/or the mode switch selection member 912 to reset or reengage the mechanisms and components of deploy and clamp operations to the first mode (e.g., clamp mechanism first mode).
[0048] The adjustment and engagement of the mode switch mechanism 910 and/or the mode switch selection member 912 may be triggered by the third tooth pushing on the deployment ratchet 1212 as the ratchet engages with the third tooth 1246 . The third tooth 1246 may be irregular-shaped or has a shape that is substantially different than the shape of the first tooth and/or second tooth of the first deploy gear 1214 . The mode switch mechanism 910 may be spring-loaded, such that the engagement of the deploy ratchet 1212 with the third tooth 1246 provides sufficient adjustment or movement to allow the spring-loaded mode switch mechanism 910 to reset. The resetting of the mode switch mechanism allows the stand-off 902 member to return to a position where the clamp gears 300 of the clamp mechanism 310 is engaged and in state of the first mode (clamp mechanism first mode), as illustrated in FIG. 17A and FIG. 17B .
[0049] FIG. 17C and FIG. 17D illustrate side-views of the endo-cutter or micro-cutter and stapling system 100 illustrating that the mode switch mechanism 910 , 912 has been reset to place the endo-cutter or micro-cutter and stapling system 100 in the first mode or trocar mode. As may be appreciated from the illustrations, the clamp slide pin member 522 is positioned or resting near the tip of the clamp lock member 512 . Also, the clamp pin-release member 524 is positioned or resting in the first-level position in the substantially triangular-shaped slot 533 in the clamp lock member 512 . The first-level position may allow the clamp lock member 512 to be in a substantially horizontal level, orientation, or position.
[0050] FIG. 18A and FIG. 18B illustrate the deploy mechanism components in a deployed state illustrating that components or accessories (e.g., endo-cutter or micro-cutter) attached or coupled to the deploying components have been deployed or advanced to their deployed state. For example, an endo-cutter or micro-cutter may be coupled to the deploy mechanism 1010 (such as by way of the deployment slide member 1032 and deployment spool member 1042 ). As the deploy mechanism components are advanced in various modes, the endo-cutter or micro-cutter is correspondingly advanced forward to cut target tissue as part of the clamping, cutting, and stapling of the endo-cutter or micro-cutter and stapling system operations.
[0051] Multiple features, aspects, and embodiments of the invention have been disclosed and described herein. Many combinations and permutations of the disclosed system may be useful in minimally invasive surgical procedures, and system may be configured to support various endo-cutters and/or stapling systems. One of ordinary skill in the art having the benefit of this disclosure would appreciate that the foregoing illustrated and describe features, aspects, and embodiments of the invention may be modified or altered, and it should be understood that the invention generally, as well as the specific features, aspects, and embodiments described herein, are not limited to the particular forms or methods disclosed, but also cover all modifications, equivalents and alternatives. Further, the various features and aspects of the illustrated embodiments may be incorporated into other embodiments, even if not so described herein, as will be apparent to those ordinary skilled in the art having the benefit of this disclosure. Although particular features, aspects, and embodiments of the present invention have been shown and described, it should be understood that the above discussion is not intended to limit the present invention to these features, aspects, and embodiments. It will be obvious to those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the present invention. Thus, the present invention is intended to cover alternatives, modifications, and equivalents that may fall within the spirit and scope of the following claims and their equivalents.
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A surgical stapling apparatus configured to perform stapling and/or cutting operations on a target tissue of a patient. The surgical stapling apparatus comprises of a mode selection switch to place the apparatus in either a clamping operational phase or a deployment operational phase. In the clamping operational phase, various clamp components are operated to facilitate loading of surgical staples into the stapling apparatus, if not preloaded, placement of the stapling apparatus to a target surgical site, and clamping of target tissue to be stapled and/or cut. In the deployment operational phase, various deployment components are operated to staple and/or cut the target tissue to one or more desired distance intervals to achieve the desired outcome for the surgical procedure.
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BACKGROUND
Field
Embodiments of the invention relate to shaving razors. More specifically, embodiments of the invention relate to shaving razors with a simplified cartridge interconnection feature.
Background
Many shaving razors with different handle formations exist. Some disposable razors without a replaceable blade cartridge have molded handle bolded to or formed as part of head into which one or more blades may be inserted. Such disposable razors are generally regarded as providing an inferior shave to razors with replaceable blade cartridges. The manner in which cartridges connect to the handle influences both manufacturing costs and shave quality. The existing razors generally use quite complex interconnection mechanisms typically involving numerous parts including springs, hooks, release buttons that are all discreetly formed and require separate manufacture and assembly. This increases the cost and complexity of the manufacturing process.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention are illustrated by way of example and not by way of limitation in the figures of the accompanying drawings in which like references indicate similar elements. It should be noted that different references to “an” or “one” embodiment in this disclosure are not necessarily to the same embodiment, and such references mean at least one.
FIG. 1 is an exploded view of a razor of one embodiment of the invention.
FIG. 2 is a sectional exploded view of the razor of FIG. 1 .
FIG. 3 is a sectional view illustrating the interconnection according to one embodiment of the invention.
FIG. 4 is an exploded view of an alternative embodiment of the razor handle.
FIG. 5 is a cutaway view of a razor handle with the embodiment of FIG. 4 .
DETAILED DESCRIPTION
FIG. 1 is an exploded view of a razor of one embodiment of the invention. A base member 102 is unitarily injection molded from a suitable thermoplastic. Suitable thermoplastics include resins having sufficient rigidity once cured to limit flexion of the handle such that good control of a razor cartridge attached thereto can be maintained. One suitable thermoplastic is glass-impregnated nylon with a glass content of 10-30% by weight of the mixture. This thermoplastic has been found to have suitable strength and rigidity characteristics to form a base layer for one embodiment of the instant invention.
Base member 102 defines one or more interior pockets 116 to receive mass increasing members 106 that increase the weight of the handle and therefore improve the tactile sensation for a user. In one embodiment, the pockets 116 are sized such that the weights retain the weights in a pressure fit relation such that the wall or ends of the pockets exert a force on the weight 106 to retain it with in the pocket. In one embodiment, the weights are inserted into the pockets after the base member 102 is injected and cured. In an alternative embodiment, the combined weights 106 and base 102 are formed by insert molding. While in the shown embodiment, three internal pockets 116 (and three weights 106 ) are present, other configurations of weights and pockets are within the scope and contemplation of the invention. Base member 102 also has formed as a part thereof, in the single molding operation, an interconnection feature 112 formed to engage a blade cartridge. Interconnection feature 112 is described in greater detail with respect to FIGS. 2 and 3 below.
In one embodiment, elastomeric reinforcement 104 is over molded onto base member 102 in a second injection during manufacture. The elastomeric reinforcement 104 improves the tactile sensation experienced by a user holding the razor and supports the interconnection feature 112 to reduce the risk that it becomes permanently deformed during use. Additionally, the elastomeric reinforcement 104 provides additional retention of weights 106 within pockets 116 . It is preferred that weights 106 pressure fit into pockets 116 so that the elastomeric reinforcement is not the sole retaining feature, but the pressure fit is not essential to all embodiment of the invention.
A cartridge 108 includes a plurality of shaving blades that form part of a blade head. The blade head is coupled to an injection-molded yolk having a male member 118 extending therefrom. Male member 118 defines a recess 128 that can receive interconnection member 122 . The shape and construction of the head can have myriad different forms including those described in copending application Ser. No. 13/173,911 or U.S. Pat. No. 8,479,398. The cartridge interconnection features, the male member 118 with defined recess 128 , are independent of the form of the head.
Elastomeric reinforcement 104 is selected from a group of thermoplastic elastomers (TPE's) having favorable adhesive qualities relative to the thermoplastic selected for the base member. In one embodiment, the elastomer TC5PAZ available from Kraiburg TPE Corporation is selected. During manufacture the TPE is injected at high temperature, which improves the bonding characteristics with the base member 102 . In addition to the natural adhesion between elastomeric reinforcement 104 and base member 102 , base member 102 may define interstial voids into which the elastomeric resin flows during manufacture. The cured resin then further acts as an anchor within those interstial voids to prevent delamination of the elastomeric reinforcement 104 from base member 102 .
FIG. 2 is a sectional exploded view of a razor of one embodiment of the invention. Base member 102 is shown with mass increasing members 106 residing in pockets therein. Additionally, a female receiver 232 defined by base member 102 can be seen. Female receiver 232 is dimensioned to receive male member 118 of blade cartridge 108 . Interconnection member 112 includes a living hinge 212 and a tine 222 . Living hinge 212 is manufactured to bias tine 222 into female receiver 232 such that when male member 118 is inserted into the female receiver 232 the tine 222 engages (seats within) recess 128 .
Elastomeric reinforcement 104 includes a living hinge reinforcement portion 214 that supports the interconnection member 112 . Portion 214 increases the bias of living hinge 212 into female receiver 232 . Portion 214 also reduces the risk that living hinge 212 will move beyond the elastic region of the underlying material into the plastic region resulting in permanent deformation. It has been found that this construction allows the living hinge to endure thousands of cycles without breakage.
While in one embodiment, the living hinge 212 is supported by the elastomeric reinforcement portion 214 , in other embodiments, other resilient members could be used. For example, a spring may reside in a spring housing that is molded as par of the base member. In one embodiment, the spring would reside forward of the living hinge and bias it toward the female receiver. In this context “forward” of the living hinge is deemed to mean the direction closer to the head end of the handle. The spring hosing may be sealed with a snap fit cover. Generally, the selected resilient member how ever constituted exerts a bias force on the living hinge as described and also helps to prevent permanent deformation of the interconnection member.
FIG. 3 is a sectional view illustrating the interconnection according to one embodiment of the invention. In this Figure, elastomeric reinforcement member 104 is shown residing on base member 102 . Interconnection feature 112 with its living hinge 212 can be seen with its tine 222 extending into female receiver 232 . Interconnection reinforcement portion 214 is shown supporting living hinge 212 and the remainder of interconnection feature 112 . When male member 118 of blade cartridge 108 is inserted into female receiver 232 , living hinge 212 flexes to allow the leading edge of male member 118 to pass and then the bias force of living hinge 212 and reinforcement portion 214 bias the tine into engagement of recess 128 . Blade cartridge 108 is then locked in place and ready for use. To remove the blade cartridge the user need merely apply force to interconnection feature 112 to overcome the bias force of living hinge 212 and reinforcement portion 214 to release the cartridge 108 .
FIG. 4 is an exploded view of an alternative embodiment of the razor handle. In this embodiment, base member 402 defines a single pocket 426 to receive mass increasing member 406 , pocket housing 436 provides additional structural support for weight 406 . Weight 406 is pressure fit into pocket 426 after the molding of base layer 402 . In one embodiment, weight 406 can be inserted directly into pocket 426 from the bottom side of member 402 . After insertion the elastomeric reinforcement layer 404 is over molded onto base member 402 . Interconnection feature 412 of base member 402 is identical to the analogous feature described with reference to FIGS. 1-3 .
FIG. 5 is a cutaway view of a razor handle with the embodiment of FIG. 4 . Base layer 402 defines a weight pocket 426 and pocket housing 436 is molded as part thereof. In this view living hinge 512 and tine 522 of connection feature 412 can be seen. Elastomeric interconnection reinforcement portion 514 is also shown.
The described embodiments provide a high performance razor with an easy to use and low cost interconnection for replaceable blade cartridges. The handle is manufactured by injection molding, the base layer insertion of the weights within the one or more weight pockets defined within the base layer followed by the over molding of an elastomeric reinforcement layer. The simplicity of this manufacturing process yields a highly cost efficient product.
In the foregoing specification, the embodiments of the invention have been described with reference to specific embodiments thereof. It will, however, be evident that various modifications and changes can be made thereto without departing from the broader spirit and scope of the invention as set forth in the appended claims. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense.
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A reduced cost interconnection for shaving razor cartridges. A base member is injection molded as a single continuous mass. The base member defines at least one void that may receive a mass increasing member. The base member has a handle portion integrally formed with a living hinge and an interconnection feature. The interconnection feature is biased to detachably engage a counterpart interconnection feature of a blade cartridge. Elastomeric reinforcement in over molded onto the base member to improve the structural integrity of the living hinge.
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[0001] This application is a continuation application of U.S. patent application Ser. No. 10/739,109, filed Dec. 19, 2003.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a charge pump circuit and a phase locked loop (PLL) circuit using a charge pump circuit, such as a PLL circuit for generating local oscillation signals in a wireless communication system and a charge pump circuit used for the same.
[0004] 2. Description of Related Art
[0005] When a charge pump circuit is off, leakage current induces a voltage fluctuation of an output signal of the charge pump circuit and has become one of the causes of fluctuation in the oscillation frequency of a PLL circuit. For this reason, a reduction of the leakage current at the OFF time is an important characteristic required for the charge pump circuit. In recent years, power supply voltage has been lowered along with miniaturization of a semiconductor device, so it becomes necessary to lower a threshold voltage of a transistor for operation at a low voltage. Due to this, the leakage current at the OFF time of the transistor tends to increase.
[0006] FIG. 8 is a view showing an example of a charge pump circuit. As illustrated, this charge pump circuit is configured by nMOS transistors NT 1 , NT 2 , and NT 3 and pMOS transistors PT 1 , PT 2 , and PT 3 . The transistors NT 2 and NT 3 form a differential pair circuit. The transistor NT 1 is connected between a connection point of sources of the transistors NT 2 and NT 3 and a note of a ground potential and supplies a current to the differential operation pair circuit. Also, the transistors PT 2 and PT 3 form a differential operation pair circuit. The transistor PT 1 is connected between the connection point of sources of the transistors PT 2 and PT 3 and a power supply terminal of a power supply voltage V CC and supplies the current to the differential operation pair circuit.
[0007] In the charge pump circuit, the differential operation pair circuit configured by the transistors NT 2 and NT 3 outputs a discharge current I DN to an output terminal OUT in accordance with a down signal DN and its logic inverted signal DNX. Namely, in accordance with the down signal DN and its logic inverted signal DNX, a pull-in current I DN flowing from the output terminal OUT to a ground potential GND is generated. On the other hand, the differential operation pair circuit configured by the transistors PT 2 and PT 3 outputs a charge current I UP to the output terminal OUT, in accordance with an up signal UP and its logic inverted signal UPX.
[0008] The charge pump circuit controls a current value of a discharge current I DN by a bias voltage VN supplied to the gate of the transistor NT 1 and controls the current value of the charge current I UP by a bias voltage VP supplied to the gate of the transistor PT 1 . Further, the timing of the discharge current I DN and the charge current I UP is controlled by the down signal DN and the up signal UP, as explained above.
[0009] In the charge pump circuit, a reduction of the leakage current at the time of OFF can be achieved by enlarging the amplitudes of the up signal UP and its logic inverted signal UPX and the down signal DN and its logic inverted signal DNX. However, the current I DN and I UP flow through the transistors NT 3 and PT 3 also at the OFF time, so there is a problem of a large current consumption. Further, when switching the transistors NT 2 and NT 3 in accordance with the down signal DN and its logic inverted signal DNX or when switching the transistors PT 2 and PT 3 in accordance with the up signal UP and its logic inverted signal UPX, both transistors configuring the differential operation pair circuit are turned ON. For this reason, for example, when the down signal DN and its logic inverted signal DNX switch, both of the transistors NT 2 and NT 3 are turned ON, so the output terminal OUT and the supply side of the power supply voltage V CC are short circuited, and charges flow into the output terminal OUT. On the other hand, when the up signal UP and its logical inverted signal UPX switch, both of the transistors PT 2 and PT 3 are turned ON, so the output terminal OUT and the ground potential GND are short circuited, and charges flow out of the output terminal OUT.
[0010] In accordance with the inflow or outflow of the charges due to the switching of the down signal DN and the up signal UP explained above, a terminal voltage V C of a capacitor connected to the output terminal OUT of the charge pump circuit changes, so the oscillation frequency of a voltage controlled oscillator controlled by this terminal voltage V C deviates from the desired value.
[0011] In order to avoid the above problems, a charge pump circuit shown in FIG. 9 is proposed. As illustrated, in the charge pump circuit of the present example, a buffer amplifier AMP 1 is provided. A positive input terminal of the buffer amplifier AMP 1 is connected to the connection point of drains of the transistors NT 2 and PT 2 , and the output terminal thereof and a negative input terminal are connected to a connection point A of drains of the transistors NT 3 and PT 3 .
[0012] Namely, in this charge pump circuit, the buffer amplifier AMP 1 configures a voltage follower. By this, the output-terminal A of the buffer amplifier AMP 1 is held at the same voltage as that of the positive input terminal thereof. For this reason, when switching the transistors in accordance with the down signal DN and its logic inverted signal DNX or when switching the transistors in accordance with the up signal UP and its logic inverted signal UPX, the inflow or outflow of charge current from the terminal A to the output terminal OUT can be prevented.
[0013] In the charge pump circuit shown in FIG. 9 , however, the current I DN and the current I UP flow through the transistors NT 3 and PT 3 also at the OFF time, so the problem of large current consumption is not solved. Further, a buffer amplifier AMP 1 requiring an output larger than the current I DN and the current I UP is necessary, so there are problems in that the power consumption further increases and the size of the circuit becomes large.
[0014] As related art, Japanese Unexamined Patent Publication (Kokai) No. 2001-177400, Japanese Unexamined Patent Publication (Kokai) No. 2000-269808, and “A PPL Generator with 5 to 110 MHz of Lock Range for Microprocessors”, IEEE Journal of Solid - State Circuits , vol. 127, no. 11, November 1992, pp. 1599 to 1607, may be mentioned.
[0015] In order to reduce the leakage current at the OFF time in the conventional charge pump circuit explained above, a variety of measures have been taken. For example, in the charge pump circuit disclosed in Japanese Unexamined Patent Publication (Kokai) No. 2000-269808, when the current is not output, a back bias voltage is supplied to the transistor to reduce the leakage current at the OFF time.
[0016] For example, taking the circuit shown in FIG. 8 as an example, at the nMOS transistor side generating the discharge current I DN , when the current I DN is not output, a signal of a low level of, for example, the ground potential level is supplied to the gates of the transistors NT 1 and NT 2 , and a signal of a high level of, for example, the power supply voltage V CC is supplied to the gate of the transistor NT 3 . Due to this, the connection point of the sources of the transistors NT 2 and NT 3 configuring the differential operation pair circuit is held at the high level, for example, a voltage lower than the power supply voltage V CC by exactly the amount of a gate-source voltage V gs of the transistor NT 3 (V CC −V gs ) . For this reason, a back bias voltage is supplied to the transistor NT 2 to reduce the leakage current at the OFF time.
[0017] However, the signal actually determining the output timing of the discharge current I DN is the drive signal supplied to the gate of the transistor NT 2 . This drive signal is a switching control signal including the analog amplitude information. The current value of the current I DN is determined according to the amplitude. In general, it is difficult to raise this drive signal sharply. This is because a capacity in accordance with a load capacity is added to the gate of the transistor NT 2 other than the gate capacity, so a larger drivability than the usual one is needed for driving the gate of the transistor NT 2 . Further, this drive signal is not a logic signal, but an analog signal also needing amplitude information, so a buffer circuit of a logic able to easily raise the drivability cannot be used.
[0018] Note that, in the charge pump circuit shown in FIG. 8 , not only at the nMOS transistor side for generating the discharge current I DN , but also at the pMOS transistor side for generating the charge current I UP , similarly, the drive signal supplied to the gate of the transistor PT 2 is an analog signal having amplitude information, so sharp rising is difficult due to the limitation of the drivability.
[0019] Due to the above reasons, the rising characteristic of the drive signal supplied to the gate of the transistor NT 2 is poor, so it becomes impossible to drive this by a pulse signal having a short width. For this reason, in the PLL circuit connected to the output terminal OUT of the charge pump circuit, receiving the output current of the charge pump circuit, generating a control signal S C , and controlling the oscillation frequency of the voltage control oscillator (VCO) by using this control signal S C , there are the disadvantages that the precision of the control signal S C is lowered and it becomes impossible to control the oscillation frequency with a high precision.
SUMMARY OF THE INVENTION
[0020] An object of the present invention is to provide a charge pump circuit able to enhance the rising and falling characteristics of the current output, drive the current output with a short pulse, reduce the leakage current at the OFF time of not outputting the current, and realize a reduction of the power consumption and a PLL circuit using the same.
[0021] According to a first aspect of the invention, there is provided a charge pump circuit for outputting a current in a period in accordance with an effective period in accordance with an input signal held at a first level in the effective period and held at a second level in a period other than the effective period, comprising first and second transistors connected in series between a first power supply terminal and an output terminal of the charge pump circit; a third transistor connected between a connection point of the first and second transistors and a second power supply terminal; and a control signal generation circuit, the control signal generation circuit generating a first control signal for turning the first transistor on in the period in accordance with the effective period and for turning off the first transistor other than this in accordance with the input signal and supplying the first control signal to the control terminal of the first transistor, generating a second control signal for turning the second transistor on earlier than the first transistor being turned on and turning off the second transistor later than the first transistor being turned off and holding a level where a desired output current flows when the second transistor is on and supplying the second control signal to the control terminal of the second transistor, and generating a third control signal for turning off the third transistor before the second transistor being turned on turning on the third transistor after the second transistor is turned off and supplying the third control signal to the control terminal of the third transistor.
[0022] Preferably, the control signal generation circuit has a buffer for delaying the input signal by exactly a predetermined delay time and a logic gate for performing a logic operation in accordance with the input signal and an output signal of the buffer, the first control signal is generated in accordance with the output signal of the buffer, and the second control signal is generated in accordance with the output signal of the logic gate.
[0023] More preferably, the control signal generation circuit switches the level of the third control signal in accordance with a preliminary input signal having a phase advanced from the input signal, turns off the third transistor, switches the level of the third control signal in accordance with the second control signal, and turns the third transistor on.
[0024] According to a second aspect of the present invention, there is provided a PLL circuit having a phase comparison-circuit generating a phase difference signal in accordance with a phase difference between a reference clock signal and a comparison target clock signal, a charge pump circuit for outputting a current in accordance with the phase difference signal, and an oscillation circuit oscillating at a predetermined oscillation frequency in accordance with the control signal generated in accordance with the output current of the charge pump circuit, generating the comparison target clock signal in accordance with the oscillation signal, and outputting it to the phase comparison circuit, wherein the PLL circuit has a locked state detection circuit for detecting whether or not the PLL circuit is in a locked state, the charge pump circuit includes first and second transistors connected in series between a first power supply and an output terminal, a third transistor connected between a connection point of the first and second transistors and a second power supply, and a control signal generation circuit, and the control signal generation circuit generates a first control signal for turning on the first transistor in a period in accordance with an effective period of the phase difference signal when it is detected by the locked state detection circuit that the PLL circuit is in the locked state and turning off the first transistor at times other than this in accordance with the phase difference signal and supplies it to the control terminal of the first transistor, generates a second control signal for turning on the second transistor earlier than the first transistor being turned on, turning off the second transistor later than the first transistor being turned off, and holding a level where a desired output current flows when the second transistor is conductive and supplies it to the control terminal of the second transistor, and generates a third control signal for turning off the third transistor earlier than the second transistor being turned on and turning on the third transistor later than the second transistor being turned off and supplies this to the control terminal of the third transistor.
[0025] Preferably, the third transistor is held in the on state in a period where the phase difference signal is not input in the charge pump circuit, and an inverse bias voltage is supplied between a gate and a source of the second transistor.
[0026] According to a third aspect of the present invention, there is provided a PLL circuit having a phase comparison circuit for comparing a phase difference between a reference clock signal and a comparison target clock signal and outputting an up signal or a down signal in accordance with the phase difference between the reference clock signal and the comparison target clock signal, a locked state detection circuit for detecting whether or not the PLL circuit is in a locked state in accordance with the up signal or down signal, a charge pump circuit for outputting a charge current or a discharge current to an output terminal in accordance with the up signal or down signal, a filter connected to the output terminal of the charge pump circuit and outputting a control signal in accordance with the output current of the charge pump circuit, and an oscillation circuit for generating an oscillation signal at a desired frequency in accordance with the control signal and outputting the signal in accordance with the oscillation signal as the comparison target clock signal to the phase comparison circuit, wherein the charge pump circuit has first conductivity type first and second transistors connected in series between the power supply terminal and the output terminal, a third transistor connected between the connection point of the first and second transistors and a reference potential, a first control signal generation circuit for receiving the up signal, generating a first charge control signal for turning on the first transistor in accordance with the effective period of the up signal and turning off the first transistor in a period other than the effective period, supplying the same to the control terminal of the first transistor, generating a second charge control signal for turning on the second transistor earlier than the first transistor being turned on, turning off the second transistor later than the first transistor being turned off, and outputting a desired charge current to the output terminal at the time when the second transistor is on, supplying the same to the control terminal of the second transistor, generating a third charge control signal for turning off the third transistor earlier than the second transistor being turned on and turning on the third transistor later than the second transistor being turned off, and supplying the same to the control terminal of the third transistor, second conductivity type fourth and fifth transistors connected in series between the reference potential and the output terminal, a sixth transistor connected between the connection point of the fourth and fifth transistors and the power supply terminal, and a second control signal generation circuit receiving the down signal, generating a first discharge control signal for turning on the fourth transistor in accordance with the effective period of the down signal and turning off the fourth transistor in a period other than the effective period, supplying the same to the control terminal of the fourth transistor, generating a second discharge control signal for turning on the fifth transistor earlier than the fourth transistor being turned on, turning off the fifth transistor later than the fourth transistor being turned off, and outputting a desired discharge current to the output terminal at the on time, supplying the same to the control terminal of the fifth transistor, and generating a third discharge control signal for turning off the sixth transistor earlier than the fifth transistor being turned on and turning on the sixth transistor later than the fifth transistor being turned off, and supplying the same to the control terminal of the sixth transistor.
[0027] Preferably, the third transistor is held in the on state in the period where the up signal is not input, and an inverse bias voltage is supplied between the gate and the source of the second transistor.
[0028] Preferably, the sixth transistor is held in the on state in the period where the down signal is not input, and an inverse bias voltage is supplied between the gate and the source of the fifth transistor.
[0029] According to the present invention, the charge pump circuit outputs the charge current or the discharge current in accordance with the up signal or the down signal output by the phase comparison circuit. At the OFF time when the up signal and the down signal are not output, by turning on the third transistor, an inverse bias voltage is supplied between the gate and the source of the second transistor to achieve a reduction of the leakage current.
[0030] Further, when switching the second or third transistor in accordance with the up signal or the down signal, by appropriately controlling the timing of the control signal, by turning off the third transistor earlier than the second transistor being turned on, and by turning on the third transistor later than the second transistor being turned off, the second and third transistors being simultaneously on can be avoided, the release or injection of charge current from or to the output terminal of the charge pump circuit can be prevented, and the stability of the oscillation frequency of the VCO can be improved.
[0031] Further, by controlling the timing of the charge current and the discharge current output by the charge pump circuit by the lock signal supplied to the first transistor, a large drivability can be secured, the rising and falling edges of the output current can be sharply controlled, and therefore it is possible to control the oscillation frequency of the VCO with a high precision.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] The above object and features of the present invention will be more apparent from the following description of the preferred embodiments given with reference to the accompanying drawings, wherein:
[0033] FIG. 1 is a circuit diagram of a first embodiment of a charge pump circuit according to the present invention;
[0034] FIG. 2 is a circuit diagram of the configuration of a control signal generation circuit forming part of a charge pump circuit;
[0035] FIGS. 3A to 3 I are waveform diagrams showing the operation of the control signal generation circuit;
[0036] FIG. 4 is a circuit diagram of the configuration of a control signal generation circuit forming part of the charge pump circuit;
[0037] FIGS. 5A to 5 I are waveform diagrams showing the operation of the control signal generation circuit;
[0038] FIG. 6 is a circuit diagram of a second embodiment of a charge pump circuit according to the present invention;
[0039] FIG. 7 is a block diagram of an example of the configuration of a PLL circuit according to the present invention;
[0040] FIG. 8 is a circuit diagram of an example of the configuration of a conventional charge pump circuit; and
[0041] FIG. 9 is a circuit diagram of another example of the configuration of a conventional charge pump circuit.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0042] Below, an explanation will be given of embodiments of the present invention with reference to the drawings.
[0043] First Embodiment
[0044] FIG. 1 is a circuit diagram of a first embodiment of a charge pump circuit according to the present invention.
[0045] As illustrated, the charge pump circuit of the present embodiment is configured by nMOS transistors NA, NB, and NC, pMOS transistors PA, PB, and PC, and control signal generation circuits 10 and 20 .
[0046] The transistors PB and PA are connected in series between a terminal of the power supply voltage V CC and an output terminal OUT of the charge pump circuit. Namely, the source of the transistor PB is connected to the terminal supplied with the power supply voltage V CC , and the drain is connected to a source of the transistor PA. The drain of the transistor PA is connected to the output terminal OUT. The source of the transistor PC is connected to a connection point Nl between the drain of the transistor PB and the source of the transistor PA, and the drain is grounded.
[0047] The gate of the transistor PA is supplied with an analog control signal S PA output by the control signal generation circuit 10 , the gate of the transistor PB is supplied with a control signal S 1 B output by the control signal generation circuit 10 , and the gate of the transistor PC is supplied with a control signal S 1 C output by the control signal generation circuit 10 .
[0048] The transistors NA and NB are connected in series between the output terminal OUT and the ground potential. Namely, the drain of the transistor NA is connected to the output terminal OUT, and the source is connected to the drain of the transistor NB. The source of the transistor NB is grounded. The source of the transistor NC is connected to a connection point N 2 between the source of the transistor NA and the drain of the transistor NB, and the drain is connected to the terminal supplied with the power supply voltage V CC .
[0049] The gate of the transistor NA is supplied with an analog control signal S NA output by the control signal generation circuit 20 , the gate of the transistor NB is supplied with a control signal S 2 B output by the control signal generation circuit 20 , and the gate of the transistor NC is supplied with a control signal S 2 C output by the control signal generation circuit 20 .
[0050] Next, an explanation will be given of the configurations of the control signal generation circuits 10 and 20 .
[0051] FIG. 2 is a circuit diagram of an example of the configuration of the control signal generation circuit 10 .
[0052] As shown in FIG. 2 , the control signal generation circuit 10 is configured by an AND gate 11 , buffers 12 and 13 , an OR gate 14 , an inverter 15 , D-flip-flops 16 and 17 , and inverters 18 and 19 .
[0053] The AND gate 11 receives as input a lock detection signal LKDT of a lock detection circuit provided in the PLL circuit and a preliminary frequency divided clock signal PVCK. Note that the lock detection signal LKDT is activated when the PLL circuit is in the locked state, for example, held at the high level, and is held at the low level in other cases. The preliminary frequency divided clock signal PVCK is a pulse signal generated by the frequency division circuit provided in the PLL circuit and output faster than the frequency divided clock signal VCK by exactly one cycle's worth of the oscillation signal of the voltage controlled oscillator (VCO).
[0054] The output signal of the AND gate 11 is input to the clock input terminal of the D-flip-flop 17 .
[0055] The buffers 12 and 13 are cascade connected. The input terminal of the buffer 12 receives as input the up signal UP.
[0056] One terminal of the OR gate 14 receives as input the output signal of the buffer 13 , while the other input terminal receives as input the up signal UP.
[0057] The output signal of the OR gate 14 is inverted by the inverter 15 and input to the clock input terminal of the D-flip-flop 16 .
[0058] The output signal from the output terminal Q of the D-flip-flop 16 is input to a reset terminal of the D-flip-flop 17 , while the output signal from the output terminal Q of the D-flip-flop 17 is inverted by the inverter 18 and input to the reset terminal of the D-flip-flop 16 .
[0059] As shown in FIG. 2 , the control signal generation circuit 10 outputs a control signal S 1 A from the inverter 15 , inverts the output signal of the buffer 12 by the inverter 19 , and outputs the result as a control signal S 1 B . It outputs the output signal from the output terminal Q of the D-flip-flop 17 as a control signal S 1 C . Further, it generates the analog control signal S PA in accordance with the control signal S 1 A .
[0060] Below, an explanation will be given of the operation of the control signal generation circuit 10 .
[0061] The control signal generation circuit 10 outputs the control signal S 1 C when the PLL circuit is in the locked state, that is, when the lock detection signal LKDT is at the high level. At times other than this, the output signal of the AND gate 11 is held at the low level, so the D-flip-flop 17 does not operate, and the control signal S 1 C is held at the low level of the reset state. At this time, the control signals S 1 A and S 1 B are generated in accordance with the up signal UP. Namely, when the PLL circuit does not reach the locked state, the control signals S 1 A and S 1 B are output, and the oscillation frequency of the VCO in accordance with them is controlled.
[0062] FIGS. 3A to 3 I are waveform diagrams showing the operation of the control signal generation circuit 10 when reaching the locked state. Below, an explanation will be given of the operation of the control signal generation circuit 10 while referring to FIG. 2 and FIGS. 3A to 3 I.
[0063] When the preliminary frequency divided clock signal PVCK rises to the high level, the output signal of the AND gate 11 rises, and in accordance with this, as shown in FIG. 3F , the output of the D-flip-flop 17 , that is, the control signal S 1 C , changes from the low level to the high level.
[0064] Next, as shown in FIG. 3G , the control signal S 1 B switches from the high level to the low level delayed from the rising edge of the up signal UP by exactly the delay time of the buffer 12 .
[0065] The buffer 13 further delays the output signal of the buffer 12 . Namely, the up signal UP delayed by the two buffers 12 and 13 and an original up signal UP are input to the OR gate 14 together.
[0066] For this reason, the OR gate 14 outputs a pulse signal having a broader width than the control signal S 1 B . Further, the output signal of the OR gate 14 is inverted by the inverter 15 and input to the clock input terminal of the D-flip-flop 16 .
[0067] Note that the output of the inverter 15 is extracted as the control signal S 1 A . FIG. 3H shows the waveform of the control signal S 1 A . Further, in accordance with the control signal S 1 A , the analog control signal S PA having a predetermined amplitude is generated as shown in FIG. 3I . The current value of the charge current I UP is controlled in accordance with the amplitude of the analog control signal S PA .
[0068] In accordance with the rising edge of the output of the inverter 15 , the output of the D-flip-flop 16 switches to the high level, and the D-flip-flop 17 is reset in accordance with this. Namely, the control signal S 1 C falls from the high level to the low level ( FIG. 3F ).
[0069] As explained above, the control signal generation circuit 10 generates the control signals S 1 A , S 1 B , and S 1 C in accordance with the preliminary frequency divided clock signal PVCK from the frequency divider provided in the PLL circuit and the up signal UP from the phase comparison circuit. The control signals S 1 B and S 1 C are supplied to the gates of the transistors PB and PC of the charge pump circuit shown in FIG. 1 , and the analog control signal S PA having the desired amplitude is generated in accordance with the control signal S 1 A and supplied to the gate of the transistor PA. In accordance with this, the charge pump circuit outputs the charge current I UP in accordance with the amplitude of the analog control signal S PA to be supplied to the gate of the transistor PA to the output terminal OUT during an effective period of the up signal UP, that is, during the period where the up signal UP is held at the high level.
[0070] Next, an explanation will be given of the configuration of the control signal generation circuit 20 while referring to FIG. 4 .
[0071] FIG. 4 is a circuit diagram of an example of the configuration of the control signal generation circuit 20 .
[0072] As shown in FIG. 4 , the control signal generation circuit 20 is configured by an AND gate 21 , buffers 22 and 23 , an OR gate 24 , an inverter 25 , D-flip-flops 26 and 27 , and an inverter 28 .
[0073] The AND gate 21 receives as input the lock detection signal LKDT and the preliminary frequency divided clock signal PVCK. The output signal of the AND gate 21 is input to the clock input terminal of the D-flip-flop 27 .
[0074] The buffers 22 and 23 are cascade connected. The input terminal of the buffer 22 receives as input the down signal DN.
[0075] One terminal of the OR gate 24 receives as input the output signal of the buffer 23 , while the other input terminal receives as input the down signal DN.
[0076] The output signal of the OR gate 24 is inverted by the inverter 25 and input to the clock input terminal of the D-flip-flop 26 .
[0077] The output signal from the output terminal Q of the D-flip-flop 26 is input to the reset terminal of the D-flip-flop 27 , and the output signal from the output terminal Q of the D-flip-flop 27 is inverted by the inverter 28 and input to the reset terminal of the D-flip-flop 26 .
[0078] As shown in FIG. 4 , the control signal generation circuit 20 outputs the control signal S 2 A from the OR gate 24 and outputs the control signal S 2 B from the buffer 22 . It outputs the inverted signal of the output signal of the D-flip-flop 27 , that is, the output signal S of the inverter 28 , as the control signal S 2 C . Further, it generates the analog control signal S NA in accordance with the control signal S 2 A .
[0079] Below, an explanation will be given of the operation of the control signal generation circuit 20 .
[0080] The control signal generation circuit 20 outputs the control signal S 2 C when the PLL circuit reaches the locked state, that is, when the lock detection signal LKDT is at the high level, in the same way as the control signal generation circuit 10 shown in FIG. 2 . At times other than this, the output signal of the AND gate 21 is held at the low level, so the D-flip-flop 27 does not operate, and the control signal S 2 C is held at the high level of the reset state.
[0081] FIGS. 5A to 5 I are waveform diagrams showing the operation of the control signal generation circuit 20 . Below, an explanation will be given of the operation of the control signal generation circuit 20 while referring to FIG. 4 and FIGS. 5A to 5 I.
[0082] When the preliminary frequency divided clock signal PVCK rises to the high level, the output signal of the AND gate 21 rises, and the output signal of the D-flip-flop 27 rises from the low level of the reset state to the high level in accordance with this. In accordance with this, as shown in FIG. 5F , the output signal of the inverter 28 , that is, the control signal S 2 C , changes from the high level to the low level.
[0083] Next, as shown in FIG. 5G , the control signal S 2 B switches from the low level to the high level delayed from the rising edge of the down signal DN by exactly the delay time of the buffer 22 .
[0084] The buffer 23 further delays the output signal of the buffer 22 . Namely, the down signal DN delayed by the two buffers 22 and 23 and the original down signal DN are input to the OR gate 24 together.
[0085] For this reason, the OR gate 24 outputs a pulse signal having a broader width than the control signal S 2 B , and the output signal of the OR gate 24 is inverted by the inverter 25 and input to the clock input terminal of the D-flip-flop 26 .
[0086] Note that the output of the OR gate 24 is extracted as the control signal S 2 A . FIG. 5H shows a waveform of the control signal S 2 A . Further, in accordance with the control signal S 2 A , an analog control signal S NA having a predetermined amplitude is generated as shown in FIG. 5I . In accordance with the amplitude of the analog control signal S NA , the current value of the discharge current I DN is controlled.
[0087] In accordance with the rising edge of the output of the inverter 25 , the output of the D-flip-flop 26 switches to the high level, the D-flip-flop 27 is reset, and the output signal thereof falls from the high level to the low level. In accordance with this, as shown in FIG. 5F , the output signal of the inverter 28 , that is, the control signal S 2 C , rises from the low level to the high level.
[0088] As explained above, the control signal generation circuit 20 generates the control signals S 2 A , S 2 B , and S 2 C in accordance with the preliminary frequency divided clock signal PVCK and the down signal DN. The control signals S 2 B and S 2 C are supplied to the gates of the transistors NB and NC of the charge pump circuit shown in FIG. 1 , and the analog control signal S NA having a desired amplitude is generated in accordance with the control signal S 2 A and supplied to the gate of the transistor NA. In accordance with this, the charge pump circuit outputs the discharge current I DN in accordance with the amplitude of the analog control signal S NA to be supplied to the gate of the transistor NA to the output terminal OUT during the effective period of the down signal DN, that is, during the period where the down signal DN is held at the high level.
[0089] In the charge pump circuit of the present embodiment, the control signal generation circuits 10 and 20 generate the charge current I UP and the discharge current I DN in accordance with the up signal UP and the down signal DN generated by the phase comparison circuit and output the same to the output terminal OUT.
[0090] Next, an explanation will be given of the overall operation of the charge pump circuit of the present embodiment.
[0091] As explained above, the charge pump circuit of the present embodiment outputs the charge current I UP and the discharge current I DN in accordance with the up signal UP and the down signal DN.
[0092] Here, first, an explanation will be given of the operation of the portion outputting the charge current I UP in accordance with the up signal UP.
[0093] As shown in the waveform diagrams of FIGS. 3A to 3 I, at times other than the effective period of the up signal UP, that is, when the up signal UP is at the low level, the control signals S 1 A and S 1 B are held at the high level, and the control signal S 1 C is held at the low level. Further, the analog control signal S PA generated in accordance with the control signal S 1 A is held at substantially the power supply voltage V CC . For this reason, in the charge pump circuit, the transistor PC becomes on and the transistors PA and PB become off. The source voltage of the transistor PA in the off state is held at substantially the ground potential GND, and the gate voltage is held at substantially the power supply voltage V CC , so an inverse bias voltage is supplied between the gate and the source of the transistor PA. For this reason, the leakage current of the transistor PA is reduced in comparison with the case of a zero bias, that is, where VGS=O.
[0094] Next, before the rising edge of the up signal UP, the preliminary frequency divided clock signal PVCK is output. In accordance with this, the control signal S 1 C rises from the low level to the high level, and the transistor PC switches from the on state to the off state.
[0095] Next, the up signal UP rises and is held at the high level in the predetermined period. Here, the period where the up signal UP is at the high level will be referred to as the effective period.
[0096] As shown in FIGS. 3A to 3 I, according to the rising of the up signal UP, the control signals S 1 A and S 1 B sequentially switch to the low level. In accordance with the control signal S 1 A , the analog control signal S PA having a predetermined amplitude is output. Then, when the control signal S 1 B switches to the low level, both of the transistors PB and PA are in the on state, and a current path is formed from the terminal of the power supply voltage V CC to the output terminal OUT, so the charge current I UP is output to the output terminal OUT. Note that the current value of the charge current I UP is determined according to the level of the analog control signal S PA supplied to the gate of the transistor PA.
[0097] After the elapse of the effective period, the up signal UP switches to the low level. In accordance with this, the control signal S 1 B switches to the high level, and then the control signal S 1 A switches to the high level. In accordance with this, the analog control signal SA is held at the high level, for example, the level near the power supply voltage V CC . Accordingly, after the elapse of the effective period of the up signal UP, the transistors PB and PA sequentially switch to the off state.
[0098] Next, according to the rising edge of the control signal S 1 A , the control signal S 1 C switches from the high level to the low level. In accordance with this, the transistor PC switches from the off state to the on state.
[0099] As explained above, in the operation outputting the charge current I UP in accordance with the up signal UP, the transistor PC switches to the off state before the transistor PA switches to the on state, and the transistor PC switches to the on state after the transistor PA switches to the off state. Namely, in the switching operation of the transistors, the transistors PA and PC simultaneously becoming the on state is avoided, and the leakage of the charge from the output terminal OUT can be prevented. By this, the fluctuation of the terminal voltage of the capacitor in the low pass filter due to the switching of the transistors can be suppressed, and the fluctuation of the oscillation frequency of the VCO can be suppressed.
[0100] Further, the output timing of the charge current I UP is determined according to the control signal S 1 B supplied to the gate of the transistor PB. The control signal S 1 B is a logic signal of a large amplitude, and a large drivability thereof can be secured, so the rising and falling edges of the charge current I IP can be made sharper, the pulse width of the charge current I UP can be made smaller by this, the voltage level of the control signal can be controlled with a higher precision, and accordingly the oscillation frequency of the VCO can be controlled with a high precision.
[0101] Next, an explanation will be given of the output operation of the discharge current I DN in accordance with the down signal DN.
[0102] The down signal DN is held at the high level in the predetermined effective period in the same way as the up signal UP. The charge pump circuit generates the discharge current I DN in accordance with the effective period of the down signal DN. Note that the discharge current I DN is the pull-in current from the output terminal OUT of the charge pump circuit.
[0103] As shown in the waveform diagrams of FIGS. 5A to 5 I, at times other than the effective period of the down signal DN, that is, when the down signal DN is at the low level, the control signals S 2 A and S 2 B are held at the low level, and the control signal S 2 C is held at the high level. Further, the analog control signal S NA generated in accordance with the control signal S 2 A is held at substantially the ground potential GND. For this reason, the transistor NC becomes on, and the transistors NA and NB become off. Further, the source voltage of the transistor NA in the off state is held at substantially the power supply voltage V CC , and the gate voltage is held at the ground potential GND, so the inverse bias voltage is supplied between the gate and the source of the transistor NA. For this reason, the leakage current thereof is reduced in comparison with the case of the zero bias, that is, where V GS =0.
[0104] Next, the preliminary frequency divided clock signal PVCK is output before the rising edge of the down signal DN. In accordance with this, the control signal S 2 C switches from the high level to-the low level, and the transistor NC switches from the on state to the off state.
[0105] Next, the down signal DN rises and is held at the high level in the effective period.
[0106] As shown in FIG. 5 , according to the rising of the down signal DN, the control signals S 2 A and S 2 B sequentially switch to the high level. Further, in accordance with the control signal S 2 A , the analog control signal S NA having a predetermined amplitude is output. Then, when the control signal S 2 B switches to the high level, both of the transistors NB and NA are in the on state, and the current path is formed from the output terminal OUT of the charge pump circuit to the ground potential GND, so the discharge current I DN is pulled from the output terminal OUT. Note that the current value of the discharge current I DN is determined according to the level of the analog control signal S NA supplied to the gate of the transistor NA.
[0107] After the elapse of the effective period, the down signal DN switches to the low level. In accordance with this, the control signal S 2 B switches to the low level, and then the control signal S 2 A switches to the low level. The analog control signal S NA is held at the low level, for example, substantially the ground potential. For this reason, the transistors NB and NA sequentially switch to the off state when the down signal DN passes the effective period.
[0108] Next, according to the falling edge of the control signal S 2 A , the control signal S 2 C switches from the low level to the high level. In accordance with this, the transistor NC switches from the off state to the on state.
[0109] As explained above, in the operation outputting the discharge current I DN in accordance with the down signal DN, the transistor NC switches to the off state before the transistor NA switches to the on state, and the transistor NC switches to the on state after the transistor NA switches to the off state. Namely, in the switching operation of the transistors, the transistors NA and NC simultaneously becoming the on state is avoided, and the injection of charges to the output terminal OUT can be prevented. Due to this, the fluctuation of the terminal voltage of the capacity in the low pass filter due to the switching of the transistors can be suppressed, and the fluctuation of the oscillation frequency of the VCO can be suppressed.
[0110] Further, the output timing of the discharge current I DN is determined according to the control signal S 2 B supplied to the gate of the transistor NB. The control signal S 2 B is a logic signal of a large amplitude, and a large drivability thereof can be secured, so the rising and falling edges of the discharge current I DN can be made sharper, the pulse width of the discharge current I DN can be made smaller by this, the voltage level of the control signal can be controlled with a higher precision, and accordingly the oscillation frequency of the VCO can be controlled with a high precision.
[0111] As explained above, according to the charge pump circuit of the present embodiment, the charge current I UP and the discharge current I DN are generated in accordance with the up signal UP and the down signal DN from the phase comparison circuit, and at the OFF time when any of the up signal UP and the down signal DN is not output, the transistor PC and the transistor NC are turned on, thereby to hold the source voltage of the transistor PA lower than the gate voltage and hold the source voltage of the transistor NA higher than the gate voltage, whereby the inverse bias is supplied between the gate and the source of the transistors PA and NA, and the leakage current can be reduced. Further, when switching the transistors in accordance with the up signal UP or the down signal DN, by appropriately controlling the timing of the switch, the state where the transistors PA and PC are simultaneously on or the state where the transistors NA and NC are simultaneously on is avoided, the leakage or injection of charge of the output terminal OUT due to the switching of the transistors can be avoided, the fluctuation of the control voltage to be supplied to the VCO can be suppressed, and accordingly the fluctuation of the oscillation frequency of the VCO can be suppressed. Further, in the charge pump circuit of the present embodiment, the output timing of the charge current I UP and the discharge current I DN is controlled according to a logic control signal of a large amplitude to be supplied to the gates of the transistors PB and NB. For this reason, the gate drivability of the transistor can be easily raised, the rising and falling edges of the charge current I UP and the discharge current I DN can be made sharper, and accordingly the pulse width of the output current can be made smaller and the oscillation frequency of the VCO can be controlled with a high precision.
[0112] Second Embodiment
[0113] FIG. 6 is a circuit diagram of a second embodiment of a charge pump circuit according to the present invention.
[0114] As illustrated, the charge pump circuit of the present embodiment is configured by control signal generation circuits 10 A and 20 A, PMOS transistors PA, PB, and PD, and nMOS transistors NA, NB and ND.
[0115] In comparison with the first embodiment of the charge pump circuit of the present invention shown in FIG. 1 , in the charge pump circuit of the present embodiment, an NMOS transistor ND is used in place of the pMOS transistor PC, and a PMOS transistor PD is used in place of the nMOS transistor NC.
[0116] As shown in FIG. 6 , in the transistor ND, the drain is connected to the connection point N 1 of the drain of the transistor PB and the source of the transistor PA, and the source is grounded. The gate of the transistor ND is supplied with the control signal S 1 D output by the control signal generation circuit 10 A.
[0117] On the other hand, in the transistor PD, the source is connected to the terminal supplied with the power supply voltage V CC , and the drain is connected to the connection point of the source of the transistor NA and the drain of the transistor NB. Further, the gate of the transistor PD is supplied with the control signal S 2 D output by the control signal generation circuit 20 A.
[0118] Further, in the charge pump circuit of the present embodiment, the control signal S 1 D output by the control signal generation circuit 10 A is the logic inverted signal of the control signal S 1 C output by the control signal generation circuit 10 of the first embodiment explained above, and the control signal S 2 D output by the control signal generation circuit 20 A is the logic inverted signal of the control signal S 2 C output by the control signal generation circuit 20 of the first embodiment.
[0119] The charge pump circuit of the present embodiment is substantially the same in configuration as the charge pump circuit of the first embodiment of the present invention shown in FIG. 1 , except for the differences of the configuration explained above. For this reason, the charge pump circuit of the present embodiment operates in the same way as the charge pump circuit of the first embodiment and outputs the charge current I UP or the discharge current I DN to the output terminal OUT in accordance with the up signal UP or the down signal DN.
[0120] Further, at the OFF time when the up signal UP and the down signal DN are not output, the control signal generation circuits 10 A and 20 A output control signals for turning off the transistors PA and PB and turning on the transistor ND and output control signals for turning off the transistors NA and NB and turning on the transistor PD. For this reason, for example, in the transistor PA, the source voltage is held at the ground potential GND, and the gate voltage is held at substantially the power supply voltage V CC , so the inverse bias is supplied between the gate and the source, and the leakage current can be greatly reduced. In the same way, in the transistor NA, the source voltage is held at substantially the power supply voltage V CC , and the gate voltage is held at the ground potential GND, so the inverse bias is supplied between the gate and the source, and the leakage current can be greatly reduced.
[0121] Further, in the present embodiment, the source voltage of the transistor NA is raised up to substantially the power supply voltage V CC by the pMOS transistor PD at the OFF time. On the other hand, in the charge pump circuit of the first embodiment, the source voltage of the transistor NA is raised by the nMOS transistor NC, so the source voltage is lowered from the power supply voltage V CC by exactly the amount of the threshold voltage of the transistor NC. For this reason, in the charge pump circuit of the present embodiment, at the OFF time, the source voltage of the transistor NA can be held relatively higher than that in the charge pump circuit of the first embodiment, so the effect of suppressing the leakage current is improved.
[0122] Further, in the present embodiment, when switching the output of the charge current I UP and the discharge current I DN in accordance with the up signal UP and the down signal DN, by using the control signal generation circuits 10 A and 20 A to appropriately generate the control signals at the predetermined timings, the transistors PA and ND simultaneously becoming on is avoided, the release of charge from the output terminal OUT can be prevented, the transistors NA and PD simultaneously becoming on is avoided, and the injection of charge into the output terminal OUT can be prevented. For this reason, the fluctuation of the voltage level of the control signal of the VCO due to the switching can be suppressed, and the fluctuation of the oscillation frequency of the VCO can be suppressed.
[0123] Third Embodiment
[0124] FIG. 7 is a view of the configuration of an embodiment of a PLL circuit according to the present invention.
[0125] As illustrated, the PLL circuit of the present embodiment comprises a phase frequency comparison circuit 100 , a lock detection circuit 110 , a charge pump circuit 120 , a loop filter 130 , a VCO 140 , and a frequency divider 150 .
[0126] Below, an explanation will be given of the components of the PLL circuit of the present embodiment.
[0127] The phase frequency comparison circuit 100 compares the phases and frequencies of a reference clock signal RCK and the frequency divided clock signal VCK output from the frequency divider 150 and, as a result of the comparison, outputs the up signal UP or the down signal DN in accordance with the phase difference between the reference clock signal RCK and the frequency divided clock signal VCK.
[0128] The lock detection circuit 110 detects whether or not the PLL circuit is in the locked state in accordance with the up signal UP and the down signal DN from the phase frequency comparison circuit 100 . As a result of the detection, when the PLL circuit is in the locked state, it activates the lock detection signal LKDT and, for example, sets it at the high level. Note that the lock detection signal LKDT is output to the charge pump circuit 120 .
[0129] The charge pump circuit 120 outputs the charge current I UP or the discharge current I DN in accordance with the up signal UP or the down signal DN from the phase frequency comparison circuit 100 and the lock detection signal LKDT from the lock detection circuit 110 .
[0130] The charge pump circuit 120 is configured by charge pump circuits of the first or second embodiments of the present invention explained above.
[0131] The loop filter 130 is configured by, as shown in FIG. 7 , for example, a resistor R and a capacitor C cascade connected between the output terminal of the charge pump circuit and the ground potential GND. In the loop filter 130 , the capacitor C charges or discharges in accordance with the charge current I UP and the discharge current I DN output from the charge pump circuit 120 , generates a control voltage V C , and outputs this to the VCO 140 .
[0132] Note that FIG. 7 shows only an example of the configuration of the loop filter. The loop filter has other various configurations. A low pass filter including a resistor R and a capacitor C, however is the basic configuration. A common point is that the capacitor C charges or discharges in accordance with the output current of the charge pump circuit 120 to generate the control voltage V C , and the oscillation frequency of the VCO 140 is controlled based on this.
[0133] The VCO 140 is controlled in its oscillation frequency in accordance with the control voltage V C generated by the loop filter 130 . The VCO 140 generates the clock signal CK by the oscillation frequency and supplies this to the frequency divider 150 .
[0134] The frequency divider 150 divides the clock signal CK from the VCO 140 by the predetermined frequency division ratio N and outputs the divided clock signal VCK to the phase frequency comparison circuit 100 . Further, the frequency divider 150 generates the preliminary frequency divided clock signal PVCK having a phase slightly advanced from that of the frequency divided clock signal VCK and supplies this to the charge pump circuit 120 .
[0135] The preliminary frequency divided clock signal PVCK is a pulse signal having, for example, a phase advanced from the frequency divided clock signal VCK by exactly one cycle's worth of the clock signal CK. For example, when the frequency division ratio of the frequency divider 150 is N, the preliminary frequency divided clock signal PVCK is advanced in its phase from the frequency divided clock signal VCK by exactly Π/N.
[0136] Next, an explanation will be given of the operation of the PLL circuit having the above configuration.
[0137] In the phase frequency comparison circuit 100 , by comparing the phases and frequencies of the reference clock signal RCK and the frequency divided clock signal VCK, the up signal UP or the down signal DN is output in accordance with the phase difference of these clock signals.
[0138] The lock detection circuit 110 decides whether or not the PLL circuit is in the locked state in accordance with the up signal UP or the down signal DN output by the phase frequency comparison circuit 100 . As a result of the decision, when the PLL circuit is in the locked state, the lock detection signal LKDT is activated
[0139] The charge pump circuit 120 outputs the charge current I UP or the discharge current I DN in accordance with the up signal UP or the down signal DN.
[0140] In the PLL circuit of the present embodiment, as a result of the detection by the lock detection circuit 110 , when the PLL circuit is in the locked state, the charge pump circuit 120 switches the transistors in accordance with the control signal generated by the control signal generation circuit in accordance with the preliminary frequency divided clock signal PVCK and the up signal UP or down signal DN, as shown in the waveform diagrams of FIGS. 3A to 3 I and FIGS. 5A to 5 I. As a result, the leakage current at the OFF time when the up signal UP and the down signal DN are not output is reduced. Further, the level fluctuation of the control voltage V C at the OFF time is suppressed, and the fluctuation of the oscillation frequency of the VCO 140 is suppressed.
[0141] On the other hand, when the PLL circuit does not reach the locked state, the charge pump circuit 120 does not output the control signal S 1 C or S 2 C . In this case, for example, in the charge pump circuit shown in FIG. 1 , the transistors PC and NC are held in the off state, the transistors PA and PB and the transistors NA and NB are controlled in the on or off state in accordance with the up signal UP or the down signal DN, and the charge current I UP or the discharge current I DN is supplied to the output terminal OUT. In accordance with this, the loop filter 130 generates the control voltage V C in accordance with the output current of the charge pump circuit 120 , the VCO 140 controls the oscillation frequency in accordance with this, and then the PLL circuit enters into the locked state when the phases and frequencies of the frequency divided clock signal VCK from the frequency divider 150 and the reference clock signal RCK substantially coincide.
[0142] As explained above, according to the PLL circuit of the present embodiment, when it has not reached the locked state, the charge pump circuit 120 generates the charge current I UP or the discharge current I DN in accordance with the up signal UP or the down signal DN from the phase frequency comparison circuit 100 . In accordance with this, the loop filter 130 outputs the control voltage V C , and the oscillation frequency of the VCO 140 is controlled. For this reason, feedback control is carried out in the PLL circuit so that a phase difference and the difference of the frequency between the frequency divided clock signal VCK output from the frequency divider 150 and the reference clock signal RCK are converged, and control is stabilized when the PLL circuit reaches the locked state. Then, after reaching the locked state, the charge pump circuit 120 operates as shown in FIGS. 3A to 3 I and FIGS. 5A to 5 I, the generation of the leakage current at the OFF time is suppressed, and the stability of the control voltage V C and the stability of the oscillation frequency of the VCO 140 can be enhanced. Further, the pulse width of the charge current I UP and the discharge current I DN can be controlled, and it is possible to control the oscillation frequency of the VCO 140 with a high precision.
[0143] Summarizing the effects of the invention, as explained above, according to charge pump circuit of the present invention and the PLL circuit configured by using the same, at the OFF time when the up signal and the down signal are not output, by supplying an inverse bias voltage between the source and the gate of the current output use transistor, the leakage current at the OFF time can be reduced, and the stability of the oscillation frequency of the VCO can be enhanced. On the other hand, when switching the current output transistor in accordance with the up signal and the down signal, by appropriately controlling the switching timing of the transistors, the injection or release of the charge of the charge pump circuit output terminal due to the switching can be prevented, the fluctuation of the control voltage is suppressed, and the fluctuation of the oscillation frequency of the VCO can be suppressed.
[0144] Further, according to the charge pump circuit of the present invention, the timing of the current output is controlled according to the lock signal supplied to the control terminal of the current output use transistor, so the rising or falling edge of the output current can be made sharper, the width of the current pulse can be made narrower, and the oscillation frequency of the VCO can be controlled with a high precision according to this.
[0145] While the invention has been described with reference to specific embodiments chosen for purpose of illustration, it should be apparent that numerous modifications could be made thereto by those skilled in the art without departing from the basic concept and scope of the invention.
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A charge pump circuit able to enhance the rising and falling characteristics of a current output, drive the current output with a short pulse, reduce leakage current at the OFF time when a current is not output, and realize a reduction of a power consumption and a PLL circuit using same. By outputting a charge current or a discharge current in accordance with an up signal or a down signal and turning on a third transistor (PC, NC) at the OFF time when the current is not output, an inverse bias voltage is supplied between a gate and a source of the second transistor (PA, NA), whereby a reduction of the leakage current can be realized. When the second or third transistor is switched in accordance with the up signal or the down signal, the timing of the control signal is appropriately controlled, simultaneous turning on of the second and third transistors can be avoided, release or injection of charges from and to the output terminal of the charge pump circuit can be prevented, and the stability of an oscillation frequency of a VCO can be improved.
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[0001] This Application is a U.S. National Phase of the International Application No. PCT/CN2010/073131 filed on 24 May 2010 designating the U.S. and published on 2 Dec. 2010 as WO 2010/135976.
TECHNICAL FIELD
[0002] The invention relates to 1-(substituted benzyl)-5-trifluoromethyl-2(1H)pyridone compounds, preparation methods and medical applications for the same.
BACKGROUND OF THE INVENTION
[0003] Fibrosis is in a variety of organs or tissues to cause reduction of parenchyma cells therein and increase of fibrous connective tissues, while eventually bringing damage of tissue structures, dysfunction or even organ failure. Mechanism, diagnostic methods and prevention measures for fibrosis of organs or tissues have been widely studied. In prior art, a considerable progress is made in some aspects, but some key issues unresolved still exist.
[0004] U.S. Pat. No. 3,839,346A, U.S. Pat. No. 4,052,509A, U.S. Pat. No. 4,042,699 disclose 29 pyridone compounds having structural formula I as follows,
[0000]
[0000] and disclose functions of the pyridone compounds of resisting inflammation, allaying fever, reducing level of serum uric acid, relieving pain or the like, wherein 5-methyl-1-phenyl-2(1H)-pyridone (Pirfenidone, PFD) has a best activity and a lower toxicity.
[0005] U.S. Pat. No. 5,310,562 discloses 5-methyl-1-phenyl-2(1H)-pyridone for the first time in 1994, that is Pirfenidone (PFD), having an anti-fibrosis biological activity; subsequently U.S. Pat. No. 5,518,729 and U.S. Pat. No. 5,716,632 disclose N-substituted-2-(1H)pyridone described as the structural formula I and N-substituted-3-(1H)pyridone having the same anti-fibrosis function. 44 compounds are specified, most of which are known compounds derived from U.S. Pat. No. 4,052,509; and in the compounds, R1, R2, R3, and R4 are defined as methyl group or ethyl group.
[0006] Pirfenidone (PFD) is proven to have effectiveness in fibrosis prevention through in vitro and animal experiments. The pirfenidone has functions of stopping or even converting ECM accumulation and preventing or reversing fibrosis and scar formation in the experiments of animals with renal fibrosis and pulmonary fibrosis and in the clinical treatment of patients with idiopathic pulmonary fibrosis (Shimizu T, Fukagawa M, Kuroda T, et al. Pirfenidone prevents collagen accumulation in the remnant kidney in rats with partial nephrectomy. Kidney Int, 1997, 52 (Suppl 63): S239-243; Raghu G, Johnson W C, Lockhart D, et al. Treatment of idiopathic pulmonary fibrosis with a new antifibrotic agent, pirfenidone. Am J Respir Crit Care Med, 1999, 159: 1061-1069).
[0007] The applicant proposes a CN patent ZL02114190.8 and provides a class of pyridone compounds shown in the structural formula II.
[0000]
[0000] if n=1, substituent R is F, Br, or I;
if n=2, substituent R is F, Cl, Br, I, saturated linear alkyl group, oxo-substituted saturated linear alkyl group, or halo-substituted saturated linear alkyl group.
[0008] The substituent R is either at ortho-position, meta-position, para-position or the like on a benzene ring.
[0009] Pirfenidone has come into the market in Japan in 2008 for treating indications for pulmonary fibrosis, however Pirfenidone and its derivatives have strength not high enough. The clinical dose of Pirfenidone achieves 2400 mg/day.
[0010] Patents WO2007053685 and WO2006122154 disclose compounds having functions of inhibiting p38 kinase, applied to treatment of fibrosis diseases and figured in the structural formula III;
[0000]
[0000] wherein, R1-R4 each are H, alkyl, substituted allyl, alkenyl, haloalkyl, nitroalkyl, hydroxyalkyl, alkoxyl, phenyl, substituted phenyl, halogen, hydroxyl, alkoxyalkyl, carboxyl, alkoxycarbonyl, etc.; X1-X5 each are H, halogen, alkoxyl group, or hydroxyl group.
[0011] WO2007062167 also discloses compounds having functions of inhibiting p38 kinase and applied to treatment of various fibrosis diseases, wherein some structures are shown as follows:
[0000]
[0012] Some simple substituents are provided on the benzene rings of the compounds.
[0013] CN patent 200710034357 discloses some similar compounds having the above structures with anti-fibrosis activity and a compound with the anti-fibrosis activity shown in the structural formula IV.
[0000]
[0014] Those compounds are provided with TFM at 5-position of the pyridone ring with no any substitutents on aromatic ring of phenyl group, thereby overcoming the disadvantages of inferior action of Pirfenidone.
[0015] DE patent DE4343528 reports a class of compounds having insecticidal actions in agriculture, with the structural formula V as follows.
[0000]
[0000] in structural formula V, A and B are substituted by various heterocyclic rings, such as furan ring, imidazole, pyridine and pyridone; wherein a class of compounds with the structural formula VI is included.
[0000]
[0016] EP patents EP259048, EP367410 and EP398499 report a class of compounds having insecticidal actions in agriculture, with the structural formula VII as follows:
[0000]
[0000] wherein a class of compounds having the structural formula VIII, in which R 1 is pyridone and R 10 is O or S, is included.
[0000]
[0017] EP patent EP216541 reports a class of compounds having insecticidal actions in agriculture, with the structural formula IX as follows:
[0000]
[0000] wherein a class of compounds with the structural formula X is included.
[0000]
[0018] EP patent EP488220 reports a class of compounds having insecticidal actions, with the structural formula XI as follows:
[0000]
[0019] In structures of the above-mentioned compounds, the pyridine ring and the benzene ring at 1-position of the pyridine ring have a plurality of substituents; the compounds with complicated structures have not been reported to have the anti-fibrosis function. In the meanwhile, more fluorine atoms in the structure will result in stronger lipid solubility of the molecule.
[0020] DE102004027359 discloses a class of compounds capable of adjusting dopamine-3 receptor and applied to treatment of Parkinson's disease and schizophrenosis;
[0000]
[0000] wherein, A is a hydrocarbon chain with 4-6 atoms, having 1-2 substituted methyl groups thereon; or 1-2 carbon atoms in the carbon chain are substituted by O, C═O, S and other atoms; R1 and R2 are H, CN, NO2, halogen atom, OR 5 , NR 6 R 7 , C(O) N R 6 R 7 , O—C(O) N R 6 R 7 ; C1-C6 alkyl, C1-C6 haloalkyl, etc.
SUMMARY OF THE INVENTION
[0021] The invention provides 1-(substituted benzyl)-5-trifluoromethyl-2-(1H)pyridine compounds shown in structural formula XIII,
[0000]
[0000] wherein R1-R4, R12 are selected from H, CN, NO 2 , hydroxyl, amino, halogen atom, C 1 -C 6 alkoxyl, NR 10 R 11 , OR 13 , C(O)R 14 , O—C(O)R 14 R 15 , C 1 -C 6 alkyl, C 1 -C 6 haloalkyl, C 2 -C 6 alkenyl, carboxyl and carboxylic ester; wherein R1˜R4, R12 are not simultaneously H, R 14 and R 15 are selected from C 1 -C 6 alkyl; where in NR 10 R 11 , OR 13 , R 10 and R 11 are selected from H, C 1 -C 6 hydroxyalkyl, esterified C 1 -C 6 hydroxyalkyl, C 1 -C 6 alkoxyalkyl, or structural formula XIV, and R 10 and R 11 are not simultaneously H; OR 13 is selected from hydroxyalkyl, alkoxyalkyl.
[0000]
[0000] in structural formula XIV, R5 is selected from H, C 1 -C 6 alkyl, C 1 -C 6 haloalkyl, C 1 -C 6 hydroxyallyl, and C 2 -C 6 alkenyl; R6-R9 are selected from H, C 1 -C 6 alkoxyl, ═O, C 1 -C 4 alkyl, C 1 -C 4 haloalkyl, C 1 -C 4 hydroxyalkyl, and C 2 -C 4 alkenyl; X is selected from N and CH 2 ; Y is selected from N, O, and C; and n is 1-6;
and pharmaceutically available salts, including hydrochlorate, sulfate, phosphate, perchlorate, methanesulfonate, trifluoromethanesulfonate, formate, acetate, propionate, butyrate, maleate, succinate, trifluoroacetate, succinate, salicylate, DL-aspartate, D-aspartate, L-aspartate, DL-glutamate, D-glutamate, L-glutamate, glycerate, succinate, stearate, DL-tartrate, D-tartrate, L-tartrate, (+/−)-mandelate, (R)-(−)-mandelate, (S)-(+)-mandelate, citrate, mucate, maleate, malonate, benzoate, DL-malate, D-malate, L-malate, hemimalate, 1-adamantane acetate, 1-adamantane carboxylate, flavianate, sulfoacetate, (+/−)-lactate, L-(+)-lactate, D-(−)-lactate, pamoate, D-α-galacturonic acid salt, glycerate, DL-cystine salt, D-cystine salt, L-cystine salt, DL-homocystine salt, D-homocystine salt, L-homocystine salt, DL-cysteine salt, D-cysteine salt, L-cysteine salt, (4S)-hydroxy-L-proline, cyclopropane-1,1-dicarboxylate, 2,2-methyl malonate, tyrosine salt, proline salt, fumarate, 1-hydroxy-2-naphthoate, phosphonoacetate, carbonate, bicarbonate, 3-phosphonopropionate, DL-pyroglutamate, D-pyroglutamate, L-pyroglutamate, toluenesulfonate, benzenesulfonate, esilate, (+/−)-camsilate, naphthalenesulfenesulfonate, 1R-(−)-camsilate, 1S-(+)-camsilate, 1,5-napadisilate, 1,2-ethanedisulphonate, 1,3-propanedisulphonate, 3-(N-morpholino) propane sulphonate, biphenyl sulphonate, isethionate, 1-hydroxy-2-naphthalenesulfenesulfonate, dihydric phosphate, potassium hydrogen phosphate, dipotassium phosphate, potassium phosphate, sodium hydrogen phosphate, disodium phosphate, sodium phosphate, sodium dihydrogen phosphate, calcium phosphate, tertiary calcium phosphate, hexafluoro phosphate, ethenyl phosphate, 2-carboxylethyl phosphate and phenyl phosphate.
[0022] More preferably, one of R1-R4 and R12 is NR 10 R 11 or OR 13 .
[0023] According to embodiments of the invention, more preferably, others are H if one of R1˜R4 and R12 is NR 10 R 11 or OR 13 .
[0024] According to embodiments of the invention, the following compounds are preferred:
1-(4-nitrobenzyl)-5-(trifluoromethyl)pyridin-2(1H)-one; 1-(4-amino-benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one; 1-(4-((3-morpholinylpropyl)amino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one; 1-(4-(((3-piperidin-1-yl)propyl)amino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one; 1-(4-((3-(4-methyl-piperazin-1-yl)propyl)amino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one; 1-(4-((2-hydroxyethyl)amino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one; 1-(4-((2-(piperidyl-1-yl)ethyl)amino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one; 1-(4-((2-morpholinylethyl)amino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one; 1-(4-((2-(4-methyl-piperazin-1-yl)ethyl)amino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one; 1-(4-((2-(piperazin-1-yl)ethyl)amino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one; 1-(4-((2-(4-(2-hydroxyethyl)piperazin-1-yl)ethyl)amino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one; 1-(4-((2-(4-methyl-piperazin-1-yl) ethyl)amino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one dihydrochloride; 1-(4-acetamide-benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one; 1-(2,6-dichlorobenzyl)-5-(trifluoromethyl)pyridin-2(1H)-one; 1-(4-fluorobenzyl)-5-(trifluoromethyl)pyridin-2(1H)-one; 1-(2-nitrobenzyl)-5-(trifluoromethyl)pyridin-2(1H)-one; 1-(2-amino benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one; 1-(3-chlorobenzyl)-5-(trifluoromethyl)pyridin-2(1H)-one; 1-(4-methoxybenzyl)-5-(trifluoromethyl)pyridin-2(1H)-one; 1-(2-fluorobenzyl)-5-(trifluoromethyl)pyridin-2(1H)-one; 1-(2-(2-hydroxyethylamino)benzyl-5-(trifluoromethyl)pyridin-2(1H)-one; 1-(2-(2-(piperazin-1-yl)ethylamino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one; 1-(2-(2-(4-methylpiperazin-1-yl)ethylamino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one; 1-(2-acetamide-benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one; 1-(2-(2-morpholinoethylamino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one; 1-(4-(2-(2-hydroxyethoxy)ethylamino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one;
[0051] The invention also provides a synthetic method for compounds listed above, including: reacting 5-trifluoromethyl-2(1H)pyridone with substituted benzyl bromide, with DMSO as solvent, potassium carbonate as acid-binding agent to prepare a simple phenyl-substituted compound, shown in reaction formula I. The synthetic starting product trifluoromethyl pyridone is a commercial material.
[0000]
[0052] To prepare a simple amino-substituted compound, following reaction formula I to form nitro substituted derivatives; reducing the nitro substitute by iron powder in the presence of hydrochloric acid and preparing target products according to different compounds, shown in reaction formula II.
[0000]
[0053] A compound, in which an amino group is bonded to a heterocyclic ring through an aliphatic side chain, is prepared including the steps of: preparing amino-substitute; and then reacting with heterocyclic compound with haloalkyl side chains, with DMF as solvent, potassium carbonate as acid-binding agent and sodium iodide as catalyst, shown in the reaction formula III.
[0000]
[0000] or, the target product is prepared by reacting hydroxyethyl amino substitute prepared according to reaction formula II with thionyl chloride to produce chloroethyl amino substitute; and then reacting with the heterocyclic compound, shown in reaction formula IV.
[0000]
[0054] The above-mentioned compound is used for preparing a broad-spectrum medicament for fibrosis.
[0055] In the invention, based on the prior art, a substituted amino group is introduced onto the benzene ring at 1-position of pyridone; a hydrophilic group such as hydroxyl group and heterocyclic ring is introduced onto the amino group through an alkyl chain, thus obtaining a class of new pyridone compounds and salts thereof. The activity of the compounds is greatly enhanced.
[0056] The applicant finds that the produced compounds have relatively higher effects than the conventional pyridone compound by modifying the phenyl group by the substituted amino group on the basis of 1-phenyl-5-trifluoromethyl-pyridone; simultaneously the compounds including heterocyclic rings could be produced into various salts which are beneficial to being prepared into various liquid formulations.
BRIEF DESCRIPTION OF DRAWINGS
[0057] FIG. 1 HE staining for renal pathology in embodiment 28 (×200)
[0058] FIG. 2 Masson staining for renal pathology in embodiment 28 (×200)
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Example 1
Preparation of 1-(4-nitrobenzyl)-5-(trifluoromethyl)pyridin-2(1H)-one
[0059]
[0060] The preparation of 1-(4-nitrobenzyl)-5-(trifluoromethyl)pyridin-2(1H)-one includes steps of: adding 8.2 g (0.050 mol) of 5-(trifluoromethyl)pyridin-2(1H)-one in 100 ml of DMSO for dissolving; adding 16.2 g (0.075 mol) of 1-(bromomethyl)-4-nitrobenzene, 11.0 g (0.080 mol) of potassium carbonate and allowing the resulting system to react at 85° C. for 4 hours under stirring; after reaction, cooling to 40° C.; adding 100 ml of 12% ammonia solution; separating out a great amount of precipitate; filtering; dissolving the filter residue with ethyl acetate; decolorizing by active carbon; filtering; drying the filtrate by anhydrous sodium sulfate overnight; filtering out sodium sulfate; reclaiming part of solvent to form crystals; filtering to obtain the product of 1-(4-nitrobenzyl)-5-(trifluoromethyl)pyridin-2(1H)-one. The product is brown solid of 11.4 g. m.p.: 121˜123° C.; EI-MS (m/z): 288[M] + ; 1 H-NMR (CDCl 3 , 300 MHz) δppm: 5.240 (s, 2H, —CH 2 —), 6.694˜6.726 (d, 1H, J=9.6 Hz, Ar—H), 7.466˜7.482 (d, 2H, J=4.8 Hz, Ar—H), 7.495 (s, 1H, Ar—H), 7.514˜7.522 (d, 1H, J=2.4 Hz, Ar—H), 7.705 (s, 1H, Ar—H), 8.222˜8.251 (d, 1H, J=8.7 Hz, Ar—H).
Example 2
Preparation of 1-(4-amino-benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one
[0061]
[0062] The preparation of 1-(4-amino-benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one includes step of: heating 11.4 g (0.037 mol) of 1-(4-nitrobenzyl)-5-(trifluoromethyl)pyridin-2(1H)-one, 200 mL of 50% ethanol and 6.28 g (0.112 mol) of reductive iron powder to reflux; slowly adding 0.42 mL (0.004 mol) of concentrated HCl in dropwise way (dropping after dilution by 5 mL of 50% ethanol); refluxing for 4 hours under stirring; after reaction, regulating pH value to 10 by 15% KOH ethanol solution; filtering; washing the filter residues by 95% ethanol (2*10 mL); extracting by ethyl acetate (50 mL*3) after evaporating ethanol from the filtrate; drying the organic phase by anhydrous sodium sulfate overnight; filtering; and evaporating filtrate to obtain the product of 1-(4-amino-benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one. The product is brown solid powders of 9.9 g. m.p. 97˜98° C. ESI-MS (m/z): 291[M+Na]+. 1H-NMR (CDCl 3 , 300 MHz) δppm: 4.255 (br, 2H, —NH2), 5.023 (s, 2H, —CH 2 —), 6.629˜6.661 (d, 1H, J=59.6 Hz, Ar—H), 6.713˜6.740 (d, 2H, J=8.1 Hz, Ar—H), 7.137˜7.164 (d, 2H, J=8.1 Hz, Ar—H), 7.393˜7.433 (dd, 1H, J=2.4 Hz, 9.6 Hz, Ar—H), 7.627 (s, 1H, Ar—H).
Example 3
Preparation of 1-(4-((3-morpholinylpropyl)amino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one
[0063]
[0064] The preparation of 1-(4-((3-morpholinylpropyl)amino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one includes steps of adding 20 mL of N,N-dimethylformamide to dissolve 2.01 g (0.0075 mol) of 1-(4-amino-benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one; adding 0.69 g (0.005 mol) of potassium carbonate, 0.42 g (0.0025 mol) of 1-(3-chloro)propyl-morpholine and a catalytic amount of sodium iodide and allowing the resulting system to react at 130° C. for 48 hours under stirring; filtering, evaporating filtrate to dryness; and separating residues by chromatography with eluent of petroleum ether and ethyl acetate with proportion of 1:1 (2% triethylamine) to obtain yellow oil of 0.5 g. ESI-MS (m/z): 396 [M+H]+; H-NMR (CDCl 3 , 300 MHz) δppm: 1.662˜1.750 (m, 2H, —CH 2 —), 2.398˜2.569 (m, 6H, —CH 2 —), 3.103˜3.143 (t, 2H, —CH 2 —), 3.665˜3.756 (t, 4H, —CH 2 —), 4.780 (br, 1H, —NH—), 4.934 (s, 2H, —CH 2 —), 6.438˜0.607 (m, 3H, Ar—H), 7.065˜7.092 (2H, Ar—H), 7.314˜7.373 (1H, Ar—H), 7.553 (s, 1H, Ar—H).
Example 4
Preparation of 1-(4-(((3-piperidin-1-yl)propyl)amino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one
[0065]
[0066] The preparation of 1-(4-(((3-piperidin-1-yl)propyl)amino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one includes steps of: adding 12 mL of acetonitrile to dissolve 1.28 g (0.0048 mol) of 1-(4-amino-benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one; adding 1.10 g (0.008 mol) of potassium carbonate, 0.64 g (0.004 mol) of 1-(3-chloro)propylpiperidine and a catalytic amount of sodium iodide and heating the resulting system to reflux for 48 hours under stirring; filtering, evaporating filtrate to dryness; and separating residues by chromatography with eluent of petroleum ether and ethyl acetate with proportion of 1:2 (1% triethylamine) to obtain off-white of 0.22 g. m.p.: 168˜170° C. ESI-MS (m/z): 394[+H]+. 1H-NMR (CDCl 3 , 300 MHz) δ ppm: 1.582 (br, 2H, —CH 2 —), 1.859˜1.875 (m, 4H, —CH 2 —), 2.009˜2.071 (m, 4H, —CH 2 —) 2.806˜2.851 (t, 6H, —CH 2 —), 3.247˜3.286 (t, 2H, —CH 2 —), 4.252 (br, 1H, —NH—), 5.002 (s, 2H, —CH 2 —), 6.581˜6.609 (d, 2H, J=8.4 Hz, Ar—H), 6.620˜6.653 (d, 1H, J=9.9 Hz, Ar—H), 7.126˜7.154 (d, 2H, J=8.4 Hz, Ar—H), 7.385˜7.424 (dd, 1H, J=2.1 Hz, 9.6 Hz, Ar—H), 7.553 (s, 1H, Ar—H).
Example 5
Preparation of 1-(4-((3-(4-methyl-piperazin-1-yl)propyl)amino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one
[0067]
[0068] The preparation of 1-(4-((3-(4-methyl-piperazin-1-yl)propyl)amino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one includes steps of adding 3 mL of ethanol to dissolve 0.402 g (0.0015 mol) of 1-(4-amino-benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one; adding 0.088 g (0.0005 mol) of 1-(3-chloropropyl)-4-methylpiperazine and feeding a catalytic amount of potassium iodide; carrying out microwave reaction at 110° C.; after reaction, filtering; evaporating filtrate to dryness; and separating residue by column chromatography with eluent of petroleum ether and ethyl acetate with proportion of 1:2 (1% triethylamine) to obtain yellow oil of 0.13 g. ESI-MS (m/z): 409 [M+H]+. 1H-NMR (CDCl 3 , 300 MHz) δppm: 1.696˜1.802 (m, 2H, —CH 2 —), 2.264 (s, 3H, —CH 3 ), 2.427˜2.470 (m, 10H—CH 2 —), 3.094˜3.136 (t, 2H, —CH 2 —), 4.936 (s, 2H—CH 2 —), 6.488˜6.516 (d, 2H, J=8.4 Hz, Ar—H), 6.552˜6.583 (d, 1H, J=9.3 Hz, Ar—H), 7.061˜7.091 (d, 2H, J=9.0 Hz, Ar—H), 7.312˜7.352 (dd, 1H, J=2.4 Hz, 9.6 Hz, Ar—H), 7.551 (s, 1H, Ar—H).
Example 6
Preparation of 1-(4-((2-hydroxyethyl)amino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one
[0069]
[0070] The preparation of 1-(4-((2-hydroxyethyl)amino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one includes steps of: adding 100 mL of n-butanol to dissolve 8.4 g (0.03 mol) of 1-(4-amino-benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one; adding 4.1 g (0.03 mol) of potassium carbonate and 5.6 g (0.06 mol) of chloroethanol and allowing the resulting system to react at 130° C. for 12 hours under stirring; filtering; evaporating filtrate to dryness; and separating residue by column chromatography with eluent of petroleum ether and ethyl acetate with proportion of 1:1 to obtain off-white solid of 2.0 g. m.p.: 97=98° C. ESI-MS (m/z): 335 [M+Na]+.
[0071] 1H-NMR (CDCl 3 , 300 MHz) δppm: 3.293˜3.28 (t, 2H, —CH 2 —), 3.829˜3.864 (t, 2H, —CH 2 —), 5.015 (s, 2H, —CH 2 —), 6.623˜6.652 (d, 2H, J=8.7 Hz, Ar—H), 7.151˜7.179 (d, 2H, J=8.4 Hz, Ar—H), 7.383˜7.424 (dd, 1H, J=2.7 Hz, 9.6 Hz, Ar—H), 7.446˜7.4588 (dd, 1H, J=2.7 Hz, 8.1 Hz, Ar—H), 7.621 (s, 1H, Ar—H).
Example 7
Preparation of 1-(4-((2-(piperidyl-1-yl)ethyl)amino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one
[0072]
A Preparation of 1-(4-((2-chloroethyl)amino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one
[0073] The preparation of 1-(4-((2-chloroethyl)amino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one includes steps of: dissolving 2.9 mmol of 1-(4-((2-hydroxyethyl)amino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one by 30 ml of dichloromethane; adding 0.22 ml of sulfurous dichloride AND 0.44 ml of triethylamine; allowing the resulting system to react at room temperature for 12 h under stirring; and separating residue by column chromatography with eluent of petroleum ether and ethyl acetate with proportion of 3:1 to obtain white solid of 0.24 g.
[0074] EI-MS (m/z): 330[M]+. 1H-NMR (CDCl 3 , 300 MHz) δppm: 3.485˜3.525 (t, 2H, —CH 2 —), 3.689˜3.728 (t, 2H, —CH 2 —), 4.181 (br, 1H, —NH—), 5.020 (s, 2H, —CH 2 —), 6.612˜6.656 (m, 3H, Ar—H), 7.167˜7.195 (d, 2H, J=8.4 Hz, Ar—H), 7.385˜7.426 (dd, 1H, J=2.7 Hz, 9.6 Hz, Ar—H), 7.623 (s, 1H, Ar—H).
B Preparation of 1-(4-((2-(piperidyl-1-yl)ethyl)amino)benzyl)-5-(trifluoromethyl) pyridin-2(1H)-one
[0075] The preparation of 1-(4-((2-(piperidyl-1-yl)ethyl)amino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one includes steps of: dissolving 0.24 g (0.7 mmol) of 1-(4-((2-chloroethyl)amino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one in 30 mL of acetonitrile; adding 0.37 g (4.2 mmol) of piperidine; carrying out refluxing reaction for 27 hours; filtering; evaporating filtrate to dryness; and separating by column chromatography with eluent of ethyl acetate and methanol with proportion of 10:1 to obtain yellow solid of 0.27 g. m.p.: 83.6˜85.5° C. EI-MS (m/z): 379[M]+. 1H-NMR (CDCl 3 , 300 MHz) δppm: 1.672 (s, 2H, —CH 2 —), 1.872 (s, 4H, —CH 2 —), 2.817˜3.112 (br, 6H, —CH 2 —), 3.542 (s, 2H, —CH 2 —), 5.012 (s, 2H, —CH 2 —), 5.174 (br, 1H, —NH—), 6.618˜6.649 (d, 1H, J=9.3 Hz, Ar—H), 6.698˜6.726 (d, 2H, J=8.4 Hz, Ar—H), 7.152˜7.181 (d, 1H, J=8.7 Hz, Ar—H), 7.386˜7.427 (dd, 1H, J=2.7 Hz, 9.6 Hz, Ar—H), 7.627 (s, 1H, Ar—H).
Example 8
Preparation of 1-(4-((2-morpholinylethyl)amino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one
[0076]
[0077] The preparation of 1-(4-((2-morpholinylethyl)amino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one includes steps of: dissolving 0.26 g (0.79 mmol) of 1-(4-((2-chloroethyl)amino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one in 30 mL of acetonitrile; adding 0.41 g (4.7 mmol) of morpholine; carrying out refluxing reaction for 46 hours; filtering; evaporating filtrate to dryness; and separating by column chromatography with eluent of ethyl acetate and methanol with proportion of 10:1 to obtain brown oil of 0.29 g.
[0078] EI-MS (m/z): 381[M] + . 1 H-NMR (CDCl 3 , 300 MHz) δppm: 2.471˜2.484 (br, 4H, —CH 2 —), 2.614˜2.653 (t, 2H, —CH 2 —), 3.142˜3.181 (t, 2H, —CH 2 —), 3.704˜3.735 (t, 4H, —CH 2 —), 4.439 (br, 1H, —NH—), 5.012 (s, 2H, —CH 2 —), 6.597˜6.650 (m, 3H, Ar—H), 7.150˜7.178 (d, 2 H, Ar—H), 7.137˜7.417 (dd, 1H, J=2.7 Hz, 9.6 Hz, Ar—H), 7.620 (s, 1H, Ar—H).
Example 9
Preparation of 1-(4-((2-(4-methyl-piperazin-1-yl)ethyl)amino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one
[0079]
[0080] The preparation of 1-(4-((2-(4-methyl-piperazin-1-yl)ethyl)amino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one includes steps of: dissolving 0.33 g (1.0 mmol) of 1-(4-((2-chloroethyl)amino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one in 30 mL of acetonitrile; adding 0.60 g (6.0 mmol) of N-methylpiperazine; carrying out refluxing reaction for 38 hours; filtering; evaporating filtrate to dryness; and separating by column chromatography with eluent of ethyl acetate and methanol with proportion of 10:1 to obtain brown oil of 0.31 g. EI-MS (m/z): 394[M] + . 1 H-NMR (CDCl 3 , 300 MHz) δppm: 2.314 (s, 3H, —CH 3 ), 2.512 (br, 8H, —CH 2 —), 2.622˜2.661 (t, 2H, —CH 2 —), 3.152 (s, 2H, —CH 2 —), 4.436 (br, 1H, —NH—), 5.011 (s, 2H, —CH 2 —), 6.592˜6.650 (t, 3H, Ar—H), 7.147˜7.175 (d, 2H, Ar—H), 7.377˜7.417 (dd, 1H, J=2.4 Hz, 9, 6 Hz, Ar—H), 7.622 (s, 1H, Ar—H).
Example 10
Preparation 1-(4-((2-(piperazin-1-yl)ethyl)amino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one
[0081]
[0082] The preparation of 1-(4-((2-(piperazin-1-yl)ethyl)amino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one includes steps of: dissolving 0.39 g (1.2 mmol) of 1-(4-((2-chloroethyl)amino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one in 30 mL of acetonitrile; adding 0.82 g (9.6 mmol) of piperazine; carrying out refluxing reaction for 18 hours; filtering; evaporating filtrate to dryness; and separating by column chromatography with eluent of ethyl acetate and methanol with proportion of 1:1 to obtain colorless oil of 0.37 g. EI-MS (m/z): 380 [M] + . 1 H-NMR (CDCl 3 , 300 MHz) δppm: 2.445 (br, 4H, —CH 2 —), 2.593˜2.632 (t, 2H, —CH 2 —), 2.855˜2.915 (t, 4H, —CH 2 —), 3.132˜3.170 (t, 2H, —CH 2 —), 4.438 (br, 1H, —NH—), 5.011 (s, 2H, —CH 2 —), 6.595˜6.650 (t, 3H, Ar—H), 7.147˜7.175 (d, 2H, Ar—H), 7.377˜7.417 (dd, 1H, J=2.4 Hz, 9.6 Hz, Ar—H), 7.625 (s, 1H, Ar—H).
Example 11
Preparation of 1-(4-((2-(4-(2-hydroxyethyl)piperazin-1-yl)ethyl)amino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one
[0083]
[0084] The preparation of 1-(4-((2-(4-(2-hydroxyethyl)piperazin-1-yl)ethyl)amino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one includes steps of: dissolving 0.83 g (2.5 mmol) of 1-(4-((2-chloroethyl)amino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one and 2.6 g (20 mmol) of hydroxyethyl piperazine in 30 mL of acetonitrile; adding an amount of sodium iodide; carrying out refluxing reaction for 29 hours; filtering; evaporating filtrate to dryness; and separating by column chromatography with eluent of petroleum ether and ethyl acetate with proportion of 10:1 to obtain yellow oil of 0.60 g. EI-MS (m/z): 424[M] + . 1 H-NMR (CDCl 3 , 300 MHz) δppm: 2.572˜2.268 (m, 12H, —CH 2 —), 3.151˜3.150 (t, 2H, —CH 2 —), 3.638˜3.673 (t, 2H, —CH 2 —), 5.011 (s, 2H, —CH 2 —), 6.593˜6.649 (t, 3H, Ar—H), 7.148˜7.176 (d, 2H, J=8.4 Hz, Ar—H), 7.37 7˜7.418 (dd, 1H, J=2.7 Hz, 9.6 Hz, Ar—H), 7.620 (s, 1H, Ar—H).
Example 12
Preparation of 1-(4-((2-(4-methyl-piperazin-1-yl)ethyl)amino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one dihydrochloride
[0085]
[0086] The preparation of 1-(4-((2-(4-methyl-piperazin-1-yl)ethyl)amino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one dihydrochloride includes steps of: dissolving 0.12 g (1.1 mmol) of 1-(4-((2-(4-methyl-piperazin-1-yl)ethyl)amino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one by 20 ml of ethanol; adding 0.075 mL of hydrochloric acid; mixing for reaction for 40 m in under stirring; evaporating solvent to dryness to obtain 1-(2-chloro-4-(((3-piperidin-1-yl)propyl)amino)phenyl)-5-(trifluoromethyl)pyridin-2(1H)-one dihydrochloride which is yellow solid of 0.09 g. EI-MS (m/z): 394[M] + . 1 H-NMR (D 2 O) δppm: 2.961 (s, 3H, —CH 3 ), 3.182˜3.236 (t, 2H, —CH 2 —), 3.299 (s, 2H, —H), 3.389˜3.438 (t, 2H, —CH 2 —), 3.565 (br, 8H, —CH═), 5.216 (s, 2H, —CH 2 —), 6.700˜6.731 (d, 1H, Ar—H), 7.229˜7.257 (d, 2H, J=8.4 Hz, Ar—H), 7.340˜7.368 (d, 2H, J=8.4 Hz, Ar—H), 7.792˜7.823 (d, 1H, J=9.3 Hz, Ar—H), 8.275 (s, 1H, Ar—H).
Example 13
Preparation of 1-(4-acetamide-benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one
[0087]
[0088] The preparation of 1-(4-acetamide-benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one includes steps of: dissolving 1.1 mol of acetic anhydride and 0.268 g (1 mmol) of 1-(4-amino-benz yl)-5-(trifluoromethyl)pyridin-2(1H)-one in 20 ml of acetic acid; carrying out refluxing reaction for 2 hours; adding 20 ml of water and extracting by ethyl ether (2*20 mL); washing the organic phase with 15% sodium bicarbonate solution and drying the organic phase by anhydrous sodium sulfate; filtering; and evaporating filtrate; and separating residue by column chromatography with eluent of chloroform and methanol with proportion of 50:1 to obtain white solid of 0.20 g, m.p.: 225.3˜227.2° C. ESI-MS (m/z): 333 [+Na] + . 1 H-NMR (DMSO) δppm: 3.513 (s, 3H, —CH 3 ), 5.098 (s, 2H, —CH 2 —), 6.566˜6.598 (d, 1H, J=9, 6 Hz, Ar—H), 7.269˜7.296 (d, 2H, J=8.1 Hz, Ar—H), 7.524˜7.551 (d, 2H, J=8.1 Hz, Ar—H), 7.678˜7.704 (d, 1H, J=8.4 Hz, Ar—H), 8.5124 (s, 1H, Ar—H), 10.009 (s, 1H, —NH).
Example 14
Preparation of 1-(2,6-dichlorobenzyl)-5-(trifluoromethyl)pyridin-2(1H)-one
[0089]
[0090] The preparation of 1-(2,6-dichlorobenzyl)-5-(trifluoromethyl)pyridin-2(1H)-one includes steps of: dissolving 0.49 g (3.0 mmol) of 5-(trifluoromethyl)pyridin-2(1H)-one in 30 ml of DMF; adding 0.5 g (3.6 mmol) of sodium carbonate and 0.88 g (4.5 mmol) 1,3-dichloro-2-(chloromethyl)benzene; carrying out refluxing reaction for 3 hours; filtering; evaporating filtrate; and separating residue by column chromatography with eluent of petroleum ether to obtain the product 1-(2,6-dichlorobenzyl)-5-(trifluoromethyl)pyridin-2(1H)-one as light-yellow solid of 0.72 g. m.p.: 74.0˜76.0° C. EI-MS (m/z): 321 [M−1] + . 1 H-NMR (CDCl 3 , 300 MHz) δppm: 5.442 (s, 2H, —CH 2 —), 6.665˜6.697 (d, 1H, J=9.6 Hz, Ar—H), 7.266 (1H, Ar—H), 7.318˜7.431 (dd, 1H, J=7.2 Hz, 9.3 Hz, Ar—H), 7.413˜7.460 (m, 3H, Ar—H).
Example 15
Preparation of 1-(4-fluorobenzyl)-5-(trifluoromethyl)pyridin-2(1H)-one
[0091]
[0092] The preparation of 1-(4-fluorobenzyl)-5-(trifluoromethyl)pyridin-2(1H)-one includes steps of: dissolving 0.49 g (3.0 mmol) of 5-(trifluoromethyl)pyridin-2(1H)-one in 30 ml of DMF; adding 0.5 g (3.6 mmol) of sodium carbonate and 0.85 g (4.5 mmol) 1-(bromomethyl)-4-fluorobenzene; carrying out refluxing reaction for 3 hours; filtering; evaporating filtrate; and separating residue by column chromatography with eluent of petroleum ether to obtain the product 1-(4-fluorobenzyl)-5-(trifluoromethyl)pyridin-2(1H)-one as white solid of 0.72 g. m.p.: 70.1˜72.0° C. ESI-MS (m/z): 294[M+Na] + . 1 H-NMR (CDCl 3 , 300 MHz) δppm: 5.112 (s, 2H, —CH 2 —), 6.658˜6.690 (d, 1H, J=9.6 Hz, Ar—H), 7.035˜7.093 (m, 2H, Ar—H), 7.299˜7.345 (m, 2H, Ar—H), 7.4123˜7.464 (dd, 1H, J=2.7 Hz, 9.6 Hz, Ar—H), 7.649 (s, 1H, Ar—H).
Example 16
Preparation of 1-(2-nitrobenzyl)-5-(trifluoromethyl)pyridin-2(1H)-one
[0093]
[0094] The preparation of 1-(2-nitrobenzyl)-5-(trifluoromethyl) pyridin-2(1H)-one includes steps of: dissolving 12.3 g (0.075 mol) of 5-(trifluoromethyl)pyridin-2(1H)-one in 200 ml of DMF; adding 16.6 g (0.12 mol) of sodium carbonate and 24.5 g (0.113 mol) 1-(bromomethyl)-2-nitrobenzene; carrying out refluxing reaction for 4 hours; cooling to 40° C.; adding 40 ml of 15% ammonia solution; extracting by ethyl acetate (50 mL*3); decolorizing by active carbon; drying by anhydrous sodium sulfate; filtering; evaporating filtrate; and separating residue by column chromatography to obtain the product 1-(2-nitrobenzyl)-5-(trifluoromethyl)pyridin-2(1H)-one as white solid of 12.2 g. m.p.: 100.0102.0° C. EI-MS (m/z): 298[M] + . 1 H-NMR (CDCl 3 , 300 MHz) δppm: 5.547 (s, 2H, —CH 2 —), 6.698˜6.730 (d, 1H, J=9.6 Hz, Ar—H), 7.179˜7.204 (d, 1H, J=7.5 Hz, Ar—H), 7.494˜7.553 (m, 2H, Ar—H), 7.600˜7.655 (m, 1H, Ar—H), 7.794 (s, 1H, Ar—H), 8.136˜8.168 (dd, 1H, J=1.5 Hz, 8.4 Hz, Ar—H).
Example 17
Preparation of 1-(2-aminobenzyl)-5-(trifluoromethyl)pyridin-2(1H)-one
[0095]
[0096] The preparation of 1-(2-aminobenzyl)-5-(trifluoromethyl)pyridin-2(1H)-one includes steps of: heating 11.7 g (0.039 mol) of 1-(2-nitrobenzyl)-5-(trifluoromethyl)pyridin-2(1H)-one, 400 mL of 50% ethanol and 6.6 g (0.118 mol) of reductive iron powder to reflux; slowly adding 5 mL of concentrated HCl in 50% ethanol in dropwise way; refluxing for 2 hours under stirring; after reaction, cooling to 50° C.; regulating pH value to 8 by 15% KOH ethanol solution; filtering; extracting by ethyl acetate (100+100+50 mL) after evaporating ethanol from the filtrate to half volume; drying the organic phase by anhydrous sodium sulfate; filtering; and evaporating filtrate to the volume of 20 ml, to obtain the crystal product of 1-(2-aminobenzyl)-5-(trifluoromethyl)pyridin-2(1H)-one. The product is light-yellow solid. m.p.: 83.4˜85.3° C. EI-MS (m/z): 268[M] + . 1 H-NMR (CDCl 3 , 300 MHz): δppm 5.098 (s, 2H, —CH 2 —), 6.656˜6.687 (d, 1H, J=9.3 Hz, Ar—H), 6.724˜6.749 (d, 1H, J=7.5 Hz, Ar—H), 6.770˜6.795 (d, 1H, J=7.5 Hz, Ar—H), 7.164˜7.208 (m, 2H, Ar—H), 7.431-7.472 (dd, 1H, J=2.7 Hz, 9.6 Hz, Ar—H), 7.755 (s, 1H, Ar—H).
Example 18
Preparation of 1-(3-chlorobenzyl)-5-(trifluoromethyl)pyridin-2(1H)-one
[0097]
[0098] The preparation of 1-(3-chlorobenzyl)-5-(trifluoromethyl)pyridin-2(1H)-one includes steps of: dissolving 0.49 g (3.0 mmol) of 5-(trifluoromethyl)pyridin-2(1H)-one in 20 ml of DMF; adding 0.66 g (4.8 mmol) of sodium carbonate and 0.93 g (4.5 mmol) 1-(bromomethyl)-3-chlorobenzene; carrying out refluxing reaction for 3 hours; adding 40 ml of 15% ammonia solution; extracting by ethyl acetate (30+20+20 mL); drying by anhydrous sodium sulfate; filtering; evaporating filtrate; and separating residue by column chromatography with eluent of petroleum ether and ethyl acetate with proportion of 6:1 to obtain the product 1-(3-chlorobenzyl)-5-(trifluoromethyl)pyridin-2(1H)-one as colorless oil of 0.70 g. EI-MS (m/z): 287[M] + . 1 H-NMR (CDCl 3 , 300 MHz) δppm: 5.098 (s, 2H, —CH 2 —), 6.656˜6.687 (d, 1H, J=9.3 Hz, Ar—H), 7.186˜7.210 (m, 1H, Ar—H), 7.307˜7.324 (m, 3H, Ar—H), 7.442˜7.482 (dd, 1H, J=2.4 Hz, 9.6 Hz, Ar—H), 7.650 (s, 1H, Ar—H).
Example 19
Preparation of 1-(4-methoxybenzyl)-5-(trifluoromethyl)pyridin-2(1H)-one
[0099]
[0100] The preparation of 1-(4-methoxybenzyl)-5-(trifluoromethyl)pyridin-2(1H)-one includes steps of: dissolving 0.50 g (3.0 mmol) of 5-(trifluoromethyl)pyridin-2(1H)-one in 20 ml of DMF; adding 0.66 g (4.8 mmol) of sodium carbonate and 0.91 g (4.5 mmol) 1-(bromomethyl)-4-methoxybenzene; carrying out refluxing reaction for 3 hours; adding 40 ml of 15% ammonia solution; extracting by ethyl acetate (30+20+20 mL); drying by anhydrous sodium sulfate; filtering; evaporating filtrate; and separating residue by column chromatography with eluent of petroleum ether and ethyl acetate with proportion of 8:1 to obtain the product 1-(4-methoxybenzyl)-5-(trifluoromethyl)pyridin-2(1H)-one as white solid of 0.79 g. m.p.: 84.2˜86.1° C. EI-MS (m/z): 283[M] + . 1 H-NMR (CDCl 3 , 300 MHz): δppm: 3.806 (s, 3H, —CH 3 ), 5.077 (s, 2H, —CH 2 —), 6.638˜6.670 (d, 1H, J=9.6 Hz, Ar—H), 6.885˜6.891 (d, 1H, J=18 Hz, Ar—H), 6.907˜6 914 (d, 1H, J=2.1 Hz, Ar—H), 7.259˜7.287 (m, 3H, Ar—H), 7.398˜7.439 (dd, 1H, J=2.7 Hz, 9.6 Hz, Ar—H), 7.633 (s, 1H, Ar—H).
Example 20
Preparation of 1-(2-fluorobenzyl)-5-(trifluoromethyl)pyridin-2(1H)-one
[0101]
[0102] The preparation of 1-(3-chlorobenzyl)-5-(trifluoromethyl)pyridin-2(1H)-one includes steps of: dissolving 0.49 g (3.0 mmol) of 5-(trifluoromethyl)pyridin-2(1H)-one in 20 ml of DMF; adding 0.66 g (4.8 mmol) of sodium carbonate and 0.85 g (4.5 mmol) 1-(bromomethyl)-2-fluorobenzene; carrying out refluxing reaction for 3 hours; adding 40 ml of 15% ammonia solution; extracting by ethyl acetate (30+20+20 mL); drying by anhydrous sodium sulfate; filtering; evaporating filtrate; and separating residue by column chromatography with eluent of petroleum ether and ethyl acetate with proportion of 6:1 to obtain the product 1-(2-fluorobenzyl)-5-(trifluoromethyl)pyridin-2(1H)-one as colorless oil of 0.65 g. EI-MS (m/z): 271[M] + . 1 H-NMR (CDCl 3 , 300 MHz): δppm: 5.176 (s, 2H, —CH 2 —), 6.623˜6.655 (d, 1H, J=9, 6 Hz, Ar—H), 7.074˜7.178 (m, 2H, Ar—H), 7.301˜7.377 (m, 1H, Ar—H), 7.410˜7.505 (m, 2H, Ar—H), 7.795 (s, 1H, Ar—H).
Example 21
Preparation of 1-(2-(2-hydroxyethylamino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one
[0103]
[0104] The preparation of 1-(2-(2-hydroxyethylamino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one includes steps of adding 100 mL of n-butanol to dissolve 9.0 g (0.034 mol) of 1-(2-amino-benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one; adding 4.69 g (0.034 mol) of potassium carbonate and 4.1 g (0.05 mol) of chloroethanol and allowing the resulting system to react at 130° C. for 18 hours under stirring; filtering; evaporating filtrate to dryness; and separating residue by column chromatography with eluent of petroleum ether and ethyl acetate with pro portion of 5:1 to obtain 1-(2-(2-hydroxyethylamino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one as white solid of 0.5 g. m.p.: 114.0˜115.0° C. EI-MS (m/z): 312[M] + . 1 H-NMR (CDCl 3 , 300 MHz): δppm: 2.822 (s, 1H, —OH), 3.228˜3.261 (t, 2H, —CH 2 —), 3.878 (s, 2H, —CH 2 —), 5.109 (s, 2H, —CH 2 —), 5.843 (br, 1H, —NH—), 6.620˜6.647 (d, 1H, Ar—H), 6.686˜6.736 (m, 2H, Ar—H), 7.206˜7.303 (m, 2H, Ar—H), 7.458˜7.499 (dd, 1H, J=2.7 Hz, 9.6 Hz, Ar—H), 7.802 (s, 1H, Ar—H).
Example 22
Preparation of 1-(2-(2-(piperazin-1-yl)ethylaminof)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one
[0105]
A Preparation of 1-(2-((2-chloroethyl)amino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one
[0106] The preparation of 1-(2-((2-chloroethyl)amino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one includes steps of dissolving 2.2 g of 1-(2-((2-hydroxyethyl)amino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one by 40 ml of dichloromethane; adding 1.7 g of sulfurous dichloride and 1.2 g of triethylamine; allowing the resulting system to react at room temperature for 10 hours under stirring; and separating residue by column chromatography to obtain white solid of 1.5 g. m.p.: 93.5˜95.0° C. EI-MS (m/z): 330[M] + . 1 H-NMR(CDCl 3 , 300 MHz): δppm: 3.483˜3.543 (t, 2H, —CH 2 —), 3.628˜3.672 (t, 2H, —CH 2 —), 5.089 (s, 2H, —CH 2 —), 5.737˜5.753 (1H, —NH—), 6.618˜6.757 (m, 3H, Ar—H), 7.206˜7.235 (dd, 1H, J=1.2 Hz, 7.5 Hz, Ar—H), 7.250˜7.307 (dd, 1H, J=8.1 Hz, 9.0 Hz, Ar—H), 7.732 (s, 1H, Ar—H).
B Preparation of 1-(2-(2-(piperazin-1-yl)ethylaminof)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one
[0107] The preparation of 1-(2-(2-(piperazin-1-yl)ethylaminof)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one includes steps of: dissolving 0.33 g (1 mmol) of 1-(2-((2-chloroethyl)amino)benz yl)-5-(trifluoromethyl)pyridin-2(1H)-one in 20 mL of acetonitrile; adding 0.53 g (6 mmol) of anhydrous piperazine and a catalytic amount of sodium iodide; carrying out refluxing reaction for 20 hours; filtering; evaporating filtrate to dryness; and separating by column chromatography with methanol to obtain yellow oil of 0.26 g. EI-MS (m/z): 380[M] + . 1 H-NMR (CDCl 3 , 300 MHz): δppm: 2.434 (s, 4H, —CH 2 —), 2.575˜2.615 (t, 2H, —CH 2 —), 2.839˜2.853 (d, 4H, —CH 2 —), 3.181˜3.200 (d, 2H, —CH 2 —), 5.153 (s, 2H, —CH 2 —), 5.275 (s, 1H, —NH—), 6.636˜6.740 (m, 3H, Ar—H), 7.150˜7.174 (d, 1H, J=7.2 Hz, Ar—H), 7.283˜7.309 (m, 1H, Ar—H), 7.426˜7.458 (d, 1H, J=9.6 Hz, Ar—H), 7.632 (s, 1H, Ar—H).
Example 23
Preparation of 1-(2-(2-(4-methylpiperazin-1-yl)ethylamino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one
[0108]
[0109] The preparation of 1-(2-(2-(4-methylpiperazin-1-yl)ethylamino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one includes steps of: dissolving 0.33 g (1 mmol) of 1-(2-((2-chloroethyl)amino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one in 20 mL of acetonitrile; adding 0.55 g (5 mmol) of 1-methylpiperazine and a catalytic amount of sodium iodide; carrying out refluxing reaction for 20 hours; filtering; evaporating filtrate to dryness; and separating by column chromatography with ethyl acetate (2% triethylamine) to obtain product 1-(2-(2-(4-methylpiperazin-1-yl)ethylamino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one as yellow oil of 0.28 g. ESI-MS (m/z): 395[M+H] + . 1 H-NMR (CDCl 3 , 300 MHz): δppm: 2.308 (s, 3H, —CH 3 ), 2.526 (br, 8H, —CH 2 —), 2.603˜2.645 (t, 2H, —CH 2 —), 3.159˜3.216 (m, 2H, —CH 2 —), 5.059 (s, 2H, —CH 2 —), 5.148 (s, 1H, —NH—), 6.364˜6.742 (m, 3H, Ar—H), 7.157˜7.175 (d, 1H, J=7.2 Hz, Ar—H), 7.284˜7.301 (1H, Ar—H), 7.423˜7.462 (dd, 1H, J=2.4 Hz, 9.3 Hz, Ar—H), 7.631 (s, 1H, Ar—H).
Example 24
Preparation of 1-(2-acetamide-benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one
[0110]
[0111] The preparation of 1-(2-acetamide-benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one includes steps of; dissolving 1.1 mol of acetic anhydride and 0.32 g (1 mmol) of 1-(2-amino-benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one in 20 ml of acetic acid; carrying out refluxing reaction for 2 hours; adding 20 ml of water and extracting by ethyl ether (2*20 mL); washing the organic phase with 15% sodium bicarbonate solution and drying the organic phase by anhydrous sodium sulfate; filtering; and evaporating filtrate; and separating residue by column chromatography with eluent of petroleum ether and ethyl acetate with proportion of 3:1 to obtain white solid of 0.20 g. m.p.: 183.0˜185.0° C. ESI-MS (m/z): 333 [+Na] + . 1 H-NMR (CDCl 3 , 300 MHz) δppm: 2.280 (s, 3H—CH 3 ), 5.113 (s, 2H, —CH 2 —), 6.703˜6.735 (d, 1H, J=9.6 Hz, Ar—H), 7.114˜7.163 (t, 1H, Ar—H), 7.338˜7.424 (m, 2H, Ar—H), 7.516˜7.543 (dd, 1H, J=2.4 Hz, 9.3 Hz, Ar—H), 7.904 (s, 1H, Ar—H), 8.143˜8.170 (d, 1H, J=8.1 Hz, Ar—H), 9.975 (s, 1H, —NH—).
Example 25
Preparation of 1-(2-(2-morpholino ethylamino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one
[0112]
[0113] The preparation of 1-(2-(2-morpholinoethylamino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one includes steps of; dissolving 0.26 g (0.79 mmol) of 1-(2-((2-chloroethyl)amino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one in 20 mL of acetonitrile; adding 1.0 g (11.5 mmol) of morpholine and a catalytic amount of sodium iodide; carrying out refluxing reaction for 25 hours; filtering; evaporating filtrate to dryness; dissolving the residue with ethyl acetate and washing with water; drying the organic phase by anhydrous sodium sulfate; and separating by column chromatography with eluent of petroleum ether and ethyl acetate with proportion of 1:1 to obtain product 1-(2-(2-morpholinoethylamino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one as off-white of 0.18 g, m.p.: 101.0˜103.0° C. EI-MS (m/z): 381[M] + . 1 H-NMR (CDCl 3 , 300 MHz): δppm: 2.472 (s, 4H, —CH 2 —), 2.616 (s, 2H, —CH 2 —), 3.201 (s, 2H, —CH 2 —), 3.685 (s, 4H, —CH 2 —), 5.071 (s, 2H, —CH 2 —), 5.179 (s, 1H, —NH—), 6.633˜6.746 (m, 3H, Ar—H), 7.163˜7.187 (d, 1H, J=7.2 Hz, Ar—H), 7.285˜7.311 (1H, Ar—H), 7.423˜7.463 (dd, 1H, J=2.4 Hz, 9.6 Hz, Ar—H), 7.643 (s, 1H, Ar—H).
Example 26
Preparation of 1-(4-(2-(2-hydroxyethoxy)ethylamino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one
[0114]
[0115] The preparation of 1-(4-(2-(2-hydroxyethoxy)ethylamino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one includes steps of dissolving 1-(4-((2-chloroethyl)amino)benzyl)-5-(trifluoromethyl)pyridin-2(1H)-one and 0.37 g (3 mmol) of chloroethoxy ethanol in 20 mL of normal butanol; adding 0.28 g (2 mmol) of potassium carbonate and a catalytic amount of sodium iodide; carrying out refluxing reaction for 28 hours; after reaction, filtering; evaporating filtrate to dryness; and separating by column chromatography with eluent of petroleum ether and ethyl acetate with proportion of 2:1 to obtain yellow oily product of 0.22 g. EI-MS (m/z): 356[M] + . 1 H-NMR (CDCl 3 , 300 MHz) δppm: 3.312˜3.346 (t, 2H, —CH 2 —), 3.589˜3.619 (t, 2H, —CH 2 —), 3.652˜3.776 (t, 4H, —CH 2 —), 5.019 (s, 2H, —CH 2 —), 6.623˜6.679 (t, 3H, Ar—H), 7.154˜7.182 (d, 2H, Ar—H), 7.384˜7.425 (dd, 1H, J=2.7 Hz, 9.6 Hz, Ar—H), 7.619 (s, 1H, Ar—H).
Example 27
Inhibition Test of Compounds to NIH3T3 Mechanocytes
[0116] An MTT method is used and comprises steps of: culturing cells in DMEM culture medium including 5% calf serum and preparing the cells into cell suspension of 3*10<4>/ml; inoculating in 96-pore plate according to 100 mul/pore; transferring new culture medium including compounds with different concentration, fluorofenidone and 1% calf serum after cells are adhered, wherein three repeated pores are provided for each concentration; respectively adding 100 mul of MTT solution in each pore after 48 hours and 72 hours of administrating (the culture medium is prepared into 5 mg/ml and kept in dark after filtering), sucking out MTT after 4 hours; adding 150 mul of DMSO which is the dissolving liquid of MTT; after 10 min and MTT is completely dissolved, measuring OD value by ELISA reader; calculating IC50 values of fluorofenidone and measured compounds according to inhibition ratio; figuring out multiple of activities of measured compounds and fluorofenidone according to IC50 values of fluorofenidone and measured compounds; and obtaining relative IC50 value of measured compounds according to multiple and IC50 value of fluorofenidone on a certain plate.
[0000]
Inhibition activity of measured compounds to NIH3T3 mechanocyte
48 hours
72 hours
Measured
Relative IC 50
Relative IC 50
compounds
(mM)
Multiple
(mM)
Multiple
Fluorofenidone
4.43
—
3.52
—
Structure IV
1.160
3.82
0.729
4.83
Compound 1
0.552
8.03
0.470
7.50
Compound 2
1.393
3.18
1.511
2.33
Compound 3
0.424
10.46
0.229
15.39
Compound 4
0.957
4.63
0.144
24.43
Compound 5
0.141
31.39
0.098
35.83
Compound 6
1.011
4.38
0.638
5.51
Compound 7
4.179
1.06
0.340
10.36
Compound 8
0.367
12.07
0.229
15.36
Compound 9
0.181
24.53
0.120
29.38
Compound 11
0.526
8.42
0.131
26.88
Compound 13
0.128
34.55
0.068
52.14
Compound 14
0.346
12.81
0.182
19.29
Compound 15
1.078
4.11
1.093
3.22
Compound 16
1.035
4.28
1.032
3.41
Compound 17
1.808
2.45
1.271
2.77
Compound 18
1.457
3.04
1.349
2.61
Compound 19
0.301
14.72
0.384
9.16
Compound 20
0.273
16.25
0.393
8.95
Compound 21
0.664
6.67
0.587
6.00
Compound 22
0.168
26.31
0.291
12.10
Compound 25
0.368
12.04
0.264
13.33
Notes:
multiple is IC 50 value of compounds to IC 50 value of fluorofenidone
Example 28
Observation of Treatment Effect of Compound 13 to Rat Unilateral Ureteral Obstruction Renal Fibrosis Model
Materials and Methods
1. Experimental Chemicals
[0117] The compound 13 is prepared according to the method provided by the invention.
2. Experimental Animals
[0118] Nine male SD rats of 188-213 g, coming from Hunan Slac Laobratory Animals Co., Ltd., are illuminated for 12 hours every day; feed is provided by Shanghai Slac Laobratory Animals Co., Ltd.; and drinking water is provided by Department of Laboratory Animal Science of Central South University.
3. Experimental Methods
[0119] (1) Randomization: nine rats are divided into three groups at random, namely a normal group (n=3); a model group (n=3) and a treatment group (n=3) treated by compound 13 of 15 mg/kg; three rats are in a hutch; and the experimental animals are adaptively fed for two days.
[0120] (2) Unilateral Ureteral Obstruction Modeling:
[0121] The unilateral ureteral obstruction modeling comprises steps of: lumbar-injecting each rat with 10% chloral hydrate according to 0.35 ml/100 g for anesthesia, fixing on a rat fixing plate; wetting the back skin by water, tightening the skin; unhairing by elbowed surgical scissors in a way closely attaching the skin; sterilizing drape in a conventional way; making an incision of 1.0 cm in longitudinal direction at a junction of a position 1.0 cm below left costal margin and 0.8 cm next to median line of vertebral column; separating successive layers to expose left kidney and left ureter; tying off left ureter against lower pole of left kidney by a thread of 4.0 and another portion 1.0 cm therebelow; isolating ureter between those two points; flushing abdominal cavity by gentamicin physiological saline solution; and stitching successive layers of retroperitoneal space and back skins after no leakage and hemorrhage.
[0122] (3) Pharmacological intervention: intragastric administration is carried out the day before modeling operation according to one time per day for 12 days; the method is detailed as follows:
[0000] a) preparing 0.5% CMCNa solution by adding an amount of 0.9% physiological saline into CMCNa powder and preparing following groups of chemicals with 0.5% CMCNa solution as solvent.
b) lavaging the normal group by 0.5% CMC-NA of 6 ml/kg·d for one time per day.
c) lavaging the model group by 0.5% CMC-NA of 6 ml/kg·d for one time per day.
d) lavaging the treatment group treated by compound 13 of 15 mg/kg by 0.5% CMC-NA of 6 ml/kg·d for one time per day.
[0123] (4) Animal Sacrifice and Sample Collection
[0124] Each group of rats is respectively lumbar-injected with 10% chloral hydrate (0.7-0.9 ml/100 g) on 11st day after operation for excessive anesthesia until sacrifice, renal tissues on the obstruction side is fixed by 4% formaldehyde, embedded by paraffin and prepared into 4 mum-thick slices for HE staining and Masson staining.
[0125] (5) HE Staining Evaluation Standard:
[0126] HE staining slices of renal tissues are successively observed in fives fields of view of renal tubulointerstitium on upper left side, upper right side, lower left side, lower right side and middle portion by a low power lens and are evaluated according to eight indexes of renal interstitium lesion: renal tubular epithelial cell vacuolar degeneration, renal tubular ectasia, renal tubular atrophy, red cell cast, protein cast, interstitial edema, interstitial fibrosis and interstitial inflammatory cell infiltration; an average value is calculated as the index of renal tubulointerstitial lesion of the sample; and the evaluation standard is based on the reference of Radford M G Jr, Donadio J V Jr, Bergstralh E J, et al. Predicting renal outcome in IgA nephropathy. J Am Soc Nephrol, 1997, 8(2):199-207.
[0127] (6) Masson Staining Evaluation Standard
[0128] Masson staining slices of renal tissues are observed in 20 fields of vision for each sample at random under 400× light microscope; percent of blue-stain collagens in the fields of vision is calculated; an average value is determined after semi-quantitative evaluation: no positive staining, 0; <25%, 1; 25-50%, 2; 50-75%, 3; >75%, 4; and the evaluation standard is based on references.
[0000] 4. Statistical Methods: analytical method of variance of single factor is adopted.
Experimental Results
1. Pathological Evaluation Results of Renal Interstitium Lesions Through HE Staining
[0129]
[0000]
TABLE 1
comparison of indexes of renal tubulointerstitial lesions of obstruction
kidneys of rats in groups
Group
Number
Score( X ± S)
Normal group
3
0.33 ± 0.12
Model group
3
9.00 ± 1.00 ⋆⋆⋆
Compound 13 group
3
7.00 ± 0.35 ⋆⋆ **
Notes:
comparison to normal group, ⋆ p < 0.05, ⋆⋆ p < 0.01; ⋆⋆⋆ p < 0.001;
comparison to model group, *p < 0.05 , ** p < 0.01 , *** p < 0.001;
2. Pathological Evaluation Results of Renal Interstitium Lesions Through MASSON Staining
[0130]
[0000]
TABLE 2
evaluation results of renal interstitium collagens of left kidneys of rats in
groups through MASSON staining
Group
Number
Score( X ± S)
Normal group
3
0.25 ± 0.00
Model group
3
2.45 ± 0.38 ⋆⋆⋆
Compound 13 group
3
1.52 ± 0.16 ⋆⋆ **
Notes:
comparison to normal group, ⋆ p < 0.05, ⋆⋆ p < 0.01; ⋆⋆⋆ p < 0.001;
comparison to model group, *p < 0.05 , ** p < 0.01 , *** p < 0.001;
CONCLUSION
[0131] The compound 13 of 15 mg/kg can effectively treat renal fibrosis.
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1-(substituted benzyl)-5-trifluoromethyl-2(1H)pyridone compounds and their pharmaceutical acceptable salts are disclosed. The preparation methods of the compounds and their salts and the use of the same for preparing the medicaments for treating fibrosis are also disclosed. New pyridine compounds and their salts are obtained from trifluoromethyl pyridone as starting material.
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TECHNICAL FIELD
[0001] The present invention relates to a hydraulic system for a suspension system and to suspension systems for booms or rocker arms for construction equipment.
BACKGROUND
[0002] In machines used in agriculture, such as for example telescope loaders, wheel loaders, or front-end loaders on tractors, it is known to use a hydraulic suspension system that cushions the boom or the rocker arm in order to achieve an overall improvement of the vehicle suspension and riding comfort, especially when the vehicle is traveling. These types of hydraulic suspension systems use a suitable hydraulic system of valves, a hydraulic cylinder and a hydraulic accumulator. The lifting side of the hydraulic cylinder is connected to the hydraulic accumulator to achieve the required suspension by. In addition, the lowering side of the hydraulic cylinder is connected to a hydraulic tank to avoid cavitation and to enable free movement of the piston rod during the suspension process.
[0003] In order to increase safety against a sudden lowering of the boom or rocker arm, these suspension systems have a load holding device to prevent hose breaks. However, in order to lower the hydraulic cylinder it is necessary to close the tank connection of the lowering side of the hydraulic cylinder so that a required pressure can build up in order to open the load holding device. Oil will flow off from the lifting side of the hydraulic cylinder only when the load holding device has been opened.
[0004] A hydraulic system for a suspension system of this type is disclosed in EP 1 157 963 A2. The suspension system for the boom of a telescope loader is proposed. The suspension system provides a load holding device for safeguarding against a pressure drop in a hydraulic cylinder and in a hydraulic accumulator. The load holding device essentially comprises a check valve that, in combination with a controllable pressure relief valve, can be bypassed by bringing the pressure relief valve from a normally closed position into an opened position using control pressure lines. In order to avoid limiting the functionality of the suspension system, or to avoid hindering an exchange of hydraulic fluid between the hydraulic accumulator and the hydraulic cylinder, the load holding device is situated at the supply side before the hydraulic cylinder and the hydraulic accumulator. A disadvantage of this system is that it provides only one load holding device for safeguarding pressure-loaded hydraulic components. A hose break occurring between the hydraulic cylinder and the hydraulic accumulator would result in the boom falling downward, and is thus not safeguarded by the load holding device.
[0005] Therefore, a need exists to create a hydraulic system of the type described above that provides a separate safeguard for the hydraulic cylinder and the hydraulic accumulator, while at the same time providing a suspension function.
SUMMARY
[0006] In an aspect of the present invention, a hydraulic system having a first on-off valve disposed in a first line between the load holding device and the control device is provided. Further, a hydraulic accumulator between the load holding device and the first on-off valve is connected to the first hydraulic line, and the load holding device. The first on-off valve can be controlled synchronously independent of a filling pressure of the hydraulic cylinder.
[0007] The load holding device is capable of being switched from a closed position oriented in the direction of the control device into an open position, and the first on-off valve is switched from an open position into a closed position oriented in the direction of the control device. Because the first on-off valve is disposed between the hydraulic accumulator and the control device and the load holding device is disposed between the hydraulic accumulator and the hydraulic cylinder, a separate safeguard of the hydraulic cylinder and of the hydraulic accumulator is ensured.
[0008] The first on-off valve is fashioned in such a way that in the closing position it closes in the direction of the control device without leakage. In addition, due to the fact that the on-off valve and the load holding device can be switched synchronously in such a way that an opening of the load holding device is connected with a closing of the first on-off valve, it is ensured that a suspension function can take place through the hydraulic accumulator for the hydraulic cylinder.
[0009] The hydraulic system is provided with a hydraulic control pressure device that is set via a conveying means that produces a control pressure. A control pressure line for valves that are to be switched hydraulically is connected optionally to the conveying means or to the hydraulic tank, via a control pressure valve. The present invention contemplates providing an arrangement of a plurality of control pressure lines that can be operated independent of one another via additional control pressure valves, so that a plurality of hydraulically switchable on-off valves can be switched independent of one another. For example, the load holding device and the first on-off valve can then be controlled by mutually independent control pressure lines.
[0010] In order to enable hydraulic control of the load holding device from pressure prevailing in the hydraulic cylinder and by pressure provided by the control pressure device, a pressure-controlled means is provided in the form of a shuttle valve. The shuttle valve is connected at one inlet side to a first control pressure line of the control pressure device and is connected at another inlet side to a second control pressure line that is connected to a chamber of the hydraulic cylinder. Depending on the pressure occurring in the control pressure lines, the shuttle valve is fed either at the hydraulic cylinder side or at the control pressure device side. Preferably, the shuttle valve is connected to a second chamber of the hydraulic cylinder.
[0011] The first on-off valve is preferably connected to the control pressure device by a third control pressure line that branches from the first control pressure line. This ensures that the first on-off valve and the pressure-controlled means can be controlled essentially synchronously, or in parallel. The pressure-controlled means, fashioned as a shuttle valve, is connected at the outlet side to the load holding device via a fourth control pressure line, so that the load holding device can be controlled, or opened, for example, via the pressure acting in the second chamber of the hydraulic cylinder or via the pressure produced by the control pressure device.
[0012] A fifth control pressure line connected to the first chamber of the hydraulic cylinder enables the load holding device to be opened by the pressure acting in the first chamber. In this way, it is ensured that the load holding device opens when, for example, a pressure is reached that overloads the hydraulic cylinder (e.g., due to excessive loads), so that hydraulic fluid can flow out of the first chamber in a controlled manner.
[0013] Between the hydraulic accumulator and the first line there is provided a second on-off valve that can be brought into an open position or into a position that closes in one direction or in both directions. The second on-off valve connects the hydraulic accumulator to the hydraulic cylinder, so that the hydraulic cylinder can have a cushioning effect when the load holding device is opened. Preferably, the second on-off valve is fashioned in such a way that it closes without leakage, such that when it is in a position in which it closes in one direction, it closes only in the direction of the hydraulic accumulator. A design of the second on-off valve so as to close in one direction ensures that pressure compensation can take place at the hydraulic accumulator.
[0014] An additional safeguarding of the hydraulic accumulator is provided by connecting a line having a pressure relief valve to the hydraulic accumulator, which line is disposed between the second on-off valve and the hydraulic accumulator. Further, the line connects the hydraulic accumulator with the hydraulic tank. In this way, for example pressure peaks that occur in the hydraulic accumulator, which could arise when there are excessively strong cushioning movements of the hydraulic cylinder, are dissipated. The hydraulic accumulator is safeguarded against excess pressure by the pressure relief valve. Similar systems may be used in order for example to protect the conveying means against excess pressure.
[0015] In order to supply a second chamber of the hydraulic cylinder, the hydraulic system is provided with a second line that connects the control device to the second chamber. The second line allows the hydraulic cylinder to be charged with pressure at both sides, so that pressure-charged raising and lowering of the hydraulic cylinder, controlled by the control device, is provided.
[0016] A third line, which is provided with a third on-off valve and is connected to the second chamber and to the hydraulic tank, makes it possible for hydraulic fluid to flow off from the second chamber of the hydraulic cylinder independent of the setting of the control device. By opening the third on-off valve, for example, in a neutral setting of the control device (in which the first and second line are closed) a cushioning movement of the hydraulic cylinder in both directions can take place without a vacuum occurring in the second chamber (decreasing cushioning movement) and a suspension-inhibiting excess pressure occurring in the second chamber (increasing cushioning movement). For the pressure-charged lowering of the hydraulic cylinder, the third on-off valve can be closed.
[0017] The first chamber of the hydraulic cylinder can advantageously be brought into connection with the hydraulic accumulator via a fourth line. The fourth line is preferably provided with a check valve that closes in the direction of the hydraulic accumulator without leakage. In this way, pressure compensation can take place at the hydraulic accumulator, resulting in advantages in the suspension function (in that a bucking or jerking lifting of the hydraulic cylinder is avoided when the suspension function is switched active). In this exemplary embodiment, at the same time the second on-off valve should be fashioned in such a way that in the closed position it closes without leakage in both directions. In addition, it is possible to provide the fourth line with a throttle or choke instead of the check valve, so that constant but moderate pressure compensation can take place between the hydraulic cylinder and the hydraulic accumulator in both directions.
[0018] It is also conceivable to situate the throttle in a parallel circuit to the check valve. This would have the advantage that an unthrottled pressure compensation can always take place at the hydraulic accumulator in the direction of the hydraulic cylinder, so that even in the case of rapid load changes the same pressure can always arise in the hydraulic cylinder, and a brief slackening or slumping of the hydraulic cylinder is also avoided.
[0019] In order to check whether the hydraulic cylinder is situated in a position that is preferred for the activation of the suspension, for example, in a fully lowered position, a sensor can be provided. The sensor can be fashioned as a contact switch or as an angle sensor that is coupled to the movement of the hydraulic cylinder and thus to its position. Depending on the output of the sensor, the suspension function can then be activated or blocked.
[0020] In order to check whether the hydraulic cylinder is in a pressure state that is preferred for the activation of the suspension, for example, in a state charged with low pressure or in a pressureless state, a pressure sensor or pressure switch can be provided. Depending on the output of the sensor or switch, the suspension function can then be activated or blocked.
[0021] Via the control pressure device, one or more on-off valves can be controlled. In an exemplary embodiment, the load holding device and the first on-off valve are controlled via the first control pressure line and via the shuttle valve, so that a synchronous switching is ensured. In additional exemplary embodiments, additional on-off valves, such as e.g. the second and the third on-off valve, can be controlled via the first control pressure line, so that by switching the first control pressure valve the load holding device and the first to third on-off valves can be switched synchronously. However, it is conceivable to carry out a controlling separate from the first control pressure line and to provide a second control pressure valve in the control pressure device, so that a controlling of additional on-off valves independent of the first control pressure valve can be carried out. For example, the load holding device and the first on-off valve can be controlled via the first control pressure line or via the first control pressure valve, and the second and third on-off valves can be controlled via a second control pressure line or via a second control pressure valve. In addition, other control combinations and variants are also conceivable.
[0022] In another exemplary embodiment, one or more on-off valves can be controlled electrically. For example, the load holding device and the first on-off valve are controlled via the control pressure device, the first control pressure valve and the second and third on-off valve being switched electrically. The suspension is then activated through electrical switching of the first control pressure valve and of the second and third on-off valves. The present invention also contemplates controlling only the load holding device via the control pressure device and to switch the first to third on-off valves electrically. For the monitoring and synchronization of electrical switching processes and switching states, an electronic control device or an electrical controller can be used.
[0023] Between the hydraulic accumulator and the first chamber, there can also be situated what is known as a pressure compensation device, which compensates the pressure in the hydraulic accumulator during a working cycle with the pressure of the first chamber. The pressure compensation device provides a pressure compensation of the hydraulic accumulator with the first chamber of the hydraulic cylinder by providing a line that has a check valve that opens in the direction of the hydraulic accumulator, this line being situated parallel to a pressure scale, pressure regulator or pressure-maintaining valve. The pressure scale is controlled dependent on the pressure prevailing in the hydraulic cylinder and in the hydraulic accumulator. Pressure compensation devices of this sort are known from the prior art and are offered for example by the firm HYDAC.
[0024] The conveying means that produces a control pressure and the conveying means that produces a filling pressure can be a joint conveying means or can form two or more separate conveying means. For example, a conveying means fashioned as a hydraulic pump can be designed and situated in such a way that it supplies on the one hand a filling pressure for the hydraulic accumulator and on the other hand also supplies a control pressure for the control pressure device via suitable pressure control means, for example via an accumulator that always supplies a constant control pressure and that is charged via the conveying means. However, the use of two separate conveying means or hydraulic pumps is also contemplated.
[0025] In the following, the present invention and its advantages, as well as advantageous developments and constructions of the present invention, are described and explained in more detail on the basis of the drawings, which indicate a plurality of exemplary embodiments of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 is a schematic diagram of a first hydraulic system, in accordance with an embodiment of the present invention;
[0027] FIG. 2 is a schematic diagram of another hydraulic system, in accordance with an embodiment of the present invention;
[0028] FIG. 3 is a schematic diagram of another hydraulic system, in accordance with an embodiment of the present invention;
[0029] FIG. 4 is a schematic diagram of another hydraulic system, in accordance with an embodiment of the present invention;
[0030] FIG. 5 is a schematic diagram of another hydraulic system, in accordance with an embodiment of the present invention;
[0031] FIG. 6 is a schematic diagram of another hydraulic system, in accordance with an embodiment of the present invention; and
[0032] FIG. 7 is a schematic representation of a loading device, fashioned as a telescope loader, having a hydraulic system in accordance with an embodiment of the present invention.
DESCRIPTION
[0033] In accordance with an embodiment of the present invention, a hydraulic system 10 for use in a suspension system of a machine is shown in FIG. 1 . Hydraulic system 10 contains a control device 12 that can be switched via an actuating device 11 . Control device 12 is, for example, a gate valve connected via hydraulic lines 14 , 16 to a conveying means 18 , for example, a hydraulic pump, and to a hydraulic tank 20 . Control device 12 , preferably, is switchable between three operating positions: lifting position, neutral position, and lowering position. The switching of control device 12 , preferably, is actuated by mechanical means, but can also be actuated electrically, hydraulically, or pneumatically.
[0034] Control device 12 is connected to a hydraulic cylinder 26 by first supply line 22 in communication with a first chamber 28 of hydraulic cylinder 26 and second supply line 24 in communication with a second chamber 30 of hydraulic cylinder 26 . A piston 29 separates the two chambers 28 , 30 from one another. First chamber 28 of hydraulic cylinder 26 represents the piston floor side, or lifting side chamber, whereas second chamber 30 represents the piston rod side, or lowering side chamber of hydraulic cylinder 26 .
[0035] A load holding device 32 , or a hose breakage safety device, is provided in first supply line 22 . Load holding device 32 has a pressure and spring controlled pressure relief valve 34 as well as a check valve 36 that opens towards the hydraulic cylinder side and is parallel connection with respect to pressure relief valve 34 via a bypass line 38 . A pressure connection is created from pressure relief valve 34 to the hydraulic-cylinder-side segment of first supply line 22 by a control pressure line 40 . Another control pressure line 42 creates a pressure connection between pressure relief valve 34 , which is held in the closed position by an adjustment spring 43 , to a shuttle valve 44 . Shuttle valve 44 is connected at its outlet side to control pressure line 42 and at its inlet side to an additional control pressure line 45 . Control pressure line 45 connects shuttle valve 44 to second supply line 24 .
[0036] A hydraulic line 46 connects first supply line 22 to a hydraulic accumulator 48 , the end 50 of hydraulic line 46 not connected to hydraulic accumulator 48 is connected between load holding device 32 and switching device 12 .
[0037] An on-off valve 52 is situated in hydraulic line 46 . On-off valve 52 represents an electrically switchable seat or globe valve that is held in the closed position by an adjustment spring 54 and can be brought into an open position by a magnetic coil 56 . However, on-off valve 52 can also be fashioned so as to be hydraulically switchable.
[0038] In the closed position, on-off valve 52 closes in the direction of hydraulic accumulator 48 . On-off valve 52 can also be fashioned so that it seals in both directions without leakage. In the open position, a hydraulic flow is ensured in both directions in order to create a suspension function between hydraulic cylinder 26 and hydraulic accumulator 48 .
[0039] Between end 50 of hydraulic line 46 and control device 12 , an additional on-off valve 60 is provided in first supply line 22 . In its normal position, on-off valve 60 is held in an open position by an adjustment spring 62 . Via a control pressure line 64 , second on-off valve 60 can be brought into a closed position, the on-off valve closing in the direction of control device 12 without leakage. Here it is also possible to fashion on-off valve 60 so as to be electrically switchable.
[0040] Second supply line 24 is connected to hydraulic tank 20 via an additional line 66 , an on-off valve 68 is situated in line 66 . On-off valve 68 is preferably fashioned as a seat valve and can be switched electrically into an open position or can be brought into a position that closes in the direction of hydraulic tank 20 . Alternatively, on-off valve 68 may be configured to be hydraulically or pneumatically switchable.
[0041] Hydraulic system 10 includes a control pressure device 70 . Control pressure device 70 has an additional conveying means 72 that is connected to hydraulic tank 20 . In addition, control pressure device 70 has a control pressure valve 74 that is connected via a supply line 76 to conveying means 72 and via an additional supply line 78 to hydraulic tank 20 . Control pressure valve 74 can be switched in such a way that a control pressure line 80 can be connected either to conveying means 72 or to hydraulic tank 20 . Control pressure line 80 is connected at the inlet side to shuttle valve 44 . In addition, control pressure line 80 is connected to control pressure line 64 of on-off valve 60 .
[0042] In addition, pressure relief valves 81 are provided in hydraulic system 10 , via which conveying means 18 , 72 , as well as hydraulic accumulator 48 , are connected to the hydraulic tank in order to prevent a pressure overload.
[0043] In the embodiments shown in FIGS. 1, 2 , 3 , 4 , and 6 , a sensor 82 is provided that detects the position of hydraulic cylinder 26 . For example, sensor 82 can be combined as a contact switch that signals a predetermined position of piston 29 . Alternatively, this sensor 82 can also be combined as a pressure sensor or pressure switch (see FIG. 1 ), the pressure sensor or pressure switch produces a signal at a predetermined pressure of first chamber 28 .
[0044] Control device 12 is connected to a switch or sensor 84 that detects the position of control device 12 and emits a control signal to an electronic control device 86 . In addition, an activation switch 88 is provided that is connected to control unit 86 . Control unit 86 is configured to switch electrically switchable on-off valves 52 , 68 , or control pressure valve 74 .
[0045] When suspension is not activated (i.e., on-off valves 52 , 68 are in the closed position and control pressure valve 74 is switched such that control pressure line 80 is connected to hydraulic tank 20 ), the operating states “lifting,” “lowering,” and “neutral position” for hydraulic cylinder 26 are controlled as follows via control device 12 in corresponding operating positions. As is shown in FIGS. 1 to 6 , control device 12 is held in the neutral position; i.e., it is closed and no flow of hydraulic fluid takes place. As shown in FIGS. 1 to 6 , control device 12 is brought from the neutral position into the lifting or lowering position by means of actuating device 11 after the receipt of a control signal or by manual actuation. Actuating device 11 can also be operated electrically, hydraulically, or pneumatically.
[0046] In the lifting position, the connection of first supply line 22 to conveying means 18 and the connection of second supply line 24 to hydraulic tank 20 are created. Conveying means 18 , connected to hydraulic tank 20 , fills first chamber 28 of hydraulic cylinder 26 via first supply line 22 and via on-off valve 60 , which is in the open position, as well as via check valve 36 of load holding device 32 (pressure relief valve 34 of load holding device 32 is in the closed position). As a result, piston 29 moves in the direction of second chamber 30 , and presses the oil situated there through second supply line 24 into hydraulic tank 20 . If switching now takes place back into the neutral position, control device 12 interrupts the connections to conveying means 18 and to hydraulic tank 20 , so that the pressure in the two chambers 28 , 30 of hydraulic cylinder 26 is maintained, and the movement of piston 29 is stopped and piston 29 remains stationary.
[0047] In the lowering position, the connection of first supply line 22 to hydraulic tank 20 and the connection of second supply line 24 to conveying means 18 are created. The conveying means conveys oil into second chamber 30 of hydraulic cylinder 26 , and the pressure building up in second supply line 24 opens pressure relief valve 34 of load holding device 32 via control pressure line 45 , and also opens shuttle valve 44 and control pressure line 42 . At the same time, piston 29 is moved in the direction of first chamber 28 , so that the oil flowing out of first chamber 28 moves into hydraulic tank 20 via first supply line 22 and via the open pressure relief valve 34 .
[0048] Load holding device 32 , thus, ensures that in the neutral position hydraulic cylinder 26 maintains its position, in the lifting and neutral position, no oil can escape from pressure-charged first chamber 28 , and that in the lowering position the oil can flow off from first chamber 28 via the opened pressure relief valve 34 . As depicted, load holding device 32 is located at the lifting side of hydraulic cylinder 26 , the lifting side being the side of hydraulic cylinder 26 in which a pressure is built up in order to lift a load. In the exemplary embodiments shown in FIGS. 1 to 6 , the lifting side is first chamber 28 of hydraulic cylinder 26 , however, by rotating hydraulic cylinder 26 , second chamber 30 could also act as the lifting side. Control pressure line 40 represents an overload safety device, so that when there are excessive operating pressures in first chamber 28 of hydraulic cylinder 26 , which could result for example from excessive carried loads or from heating of hydraulic cylinder 26 , a threshold limit pressure is reached that opens pressure relief valve 34 in order to reduce the pressure. In these states, which deviate from the normal case, pressure relief valve 34 can also be opened in the lifting and neutral positions via control pressure line 40 .
[0049] It should be noted that on-off valve 60 is open in its normal position, and permits a free flow in both directions. On-off valve 60 is closed by a hydraulic control pressure that moves on-off valve 60 into a switching position in which only a flow in the direction of lifting cylinder 26 is permitted. In the opposite direction, on-off valve 60 is leak proof such that required standards concerning the lowering of a load can be met. Shuttle valve 44 connects control pressure lines 45 , 80 , which come from control pressure valve 74 and the rod side of lifting cylinder 26 , with control pressure line 42 of pressure relief valve 34 in such a way that pressure relief valve 34 , which represents a part of load holding device 32 , can be opened. Control pressure valve 74 serves to conduct the control pressure of conveying means 72 to pressure relief valve 34 and to on-off valve 60 in order to open or close these. In the normal position, shown in FIGS. 1 to 6 , of control pressure valve 74 , control pressure lines 42 , 64 , 80 are relieved of stress towards hydraulic tank 20 , so that pressure relief valve 34 and on-off valve 60 are in the normal position (pressure relief valve 34 is closed and on-off valve 60 is open). If control pressure valve 74 is switched, hydraulic fluid flows via control pressure lines 42 , 64 , 80 to pressure relief valve 34 and to on-off valve 60 . In this way pressure relief valve 34 is opened and on-off valve 60 is closed.
[0050] In order to ensure optimal protection when a hose breaks, hydraulic cylinder 26 , load holding device 32 , on-off valve 52 , hydraulic accumulator 48 , and on-off valve 60 , as well as the connecting lines, are preferably parts of an assembly made of steel. This can be a valve block fastened to hydraulic cylinder 26 together with hydraulic accumulator 48 , or can be an assembly of valves connected to steel lines. Other parts of the hydraulic system can also be integrated into the named assemblies.
[0051] The suspension function having the specific embodiments shown in FIGS. 1 to 6 for a hydraulic system according to the present invention can be realized as described below. Shuttle valve 44 , on-off valve 52 , on-off valve 68 , and control pressure valve 74 , shown in FIGS. 1 to 6 , are utilized for the suspension function.
[0052] With reference to the exemplary embodiment shown in FIG. 1 , an activation of the suspension function is enabled by sensor 82 , connected to control unit 86 , which sensor detects a lowered position (given the use of a contact or position sensor) or a low-pressure operating state (given use of a pressure sensor) of hydraulic cylinder 26 . In order to activate the suspension function, activation switch 88 connected to control unit 86 is actuated. Control unit 86 actuates on-off valve 52 and brings this valve into an open position, through which hydraulic accumulator 48 is connected to supply line 22 . At the same time, control pressure valve 74 is controlled, which releases a control pressure and, via control pressure lines 42 , 80 in connection with shuttle valve 44 , opens pressure relief valve 34 and, via pressure control lines 64 , 80 , brings on-off valve 60 into the leakage-free closed position. In addition, on-off valve 68 connected to control unit 86 is simultaneously opened.
[0053] Through the actuation of control pressure valve 74 , a connection between the lifting side of hydraulic cylinder 26 and hydraulic accumulator 48 is accomplished and, which is sealed in leak-free fashion towards the hydraulic tank. A sudden pressure increase in first chamber 28 of hydraulic cylinder 26 (bouncing up) is not possible, because in the closed position of on-off valve 52 a flow can take place through this valve in the direction of hydraulic cylinder 26 , so that at hydraulic accumulator 48 a pressure compensation in the direction of hydraulic cylinder 26 can always take place. Hydraulic cylinder 26 can be lifted or held via the already-described operating positions, and an exchange of hydraulic fluid can take place via the open connection (on-off valve 52 is open) between hydraulic cylinder 26 and hydraulic accumulator 48 , so that a suspension function is provided. The rod side, or second chamber 30 , of hydraulic cylinder 26 is connected to hydraulic tank 20 (on-off valve 68 is open), in order to enable a free oscillation of cylinder piston 29 , or to prevent a cavitation effect in chambers 28 , 30 . If the suspension function is deactivated via activation switch 88 , on-off valves 52 , 68 , as well as control pressure valve 54 , are switched without flow. Control pressure lines 42 , 64 , 80 are here switched pressureless, whereby pressure relief valve 34 is again brought into the closed position and on-off valve 60 is again brought into the open position. It is conceivable to control pressure relief valve 34 , as well as on-off valve 60 , via separate pressure control valves (not shown) in accordance with control pressure valve 74 , in order to compensate or to take into account time delays in the response characteristic of pressure relief valve 34 or of on-off valve 60 , so that hydraulic cylinder 26 does not change its position due to an overlapping of the switching times. However, this can also be achieved hydraulically using a throttle (not shown) in control pressure line 64 .
[0054] The lowering operating state of hydraulic cylinder 26 (moving cylinder piston 29 ) is not possible when the suspension function is activated with the hydraulic system shown in FIG. 1 , because on-off valve 60 is closed in the direction of control device 12 . In order to ensure a frictionless transition from an operating state (lifting or normal position) with suspension function into the lowering operating state, the position of control device 12 is detected via sensor 84 . If control device 12 is brought into the lowering position, a control signal is automatically sent by sensor 84 to control unit 86 , and the suspension function is deactivated by switching on-off valve 52 and pressure control valve 74 . At the same time, on-off valve 68 is closed. When the suspension function is deactivated, hydraulic accumulator 48 empties via opened on-off valve 60 , and must be charged again for a new activation of the suspension function. Preferably, for this purpose hydraulic cylinder 26 is brought into a fully lowered position, so that the pressure in hydraulic cylinder 26 can build up together with the pressure in the hydraulic accumulator. A new activation of the suspension function can then take place after a new release by sensor 82 , because hydraulic cylinder 26 has been brought into its fully lowered position.
[0055] When the suspension function is activated, cylinder piston 29 can cushion freely in the lifting operating position and in the normal position. If this piston moves downward due to an impact transmitted to it, the oil is pressed from first chamber 28 into hydraulic accumulator 48 . The pressure building up in hydraulic accumulator 48 causes the oil to flow back into first chamber 28 , so that piston 29 moves upward again. This cushioning movement repeats as necessary until the impact has been completely compensated.
[0056] FIG. 2 shows an alternative exemplary embodiment in which a deactivation of the suspension function for the lowering of hydraulic cylinder 26 takes place only at times during the lowered state. Subsequently, the suspension function can be resumed without moving again into a release position detected by sensor 82 . The difference from the hydraulic system shown in FIG. 1 is that in its closed position, on-off valve 52 of hydraulic accumulator 48 closes in leak-free fashion at both sides, so that in the closed position hydraulic accumulator 48 cannot empty in the direction of hydraulic tank 20 . In addition, a pressure compensation is nonetheless ensured between hydraulic accumulator 48 and the hydraulic cylinder (this compensation is provided in the exemplary embodiment shown in FIG. 1 via on-off valve 52 in the closed position in combination with check valve 36 ), in that an additional line 92 having a check valve 90 is provided that creates a connection from second chamber 28 of hydraulic cylinder 26 to hydraulic accumulator 48 , check valve 90 closing in the direction of hydraulic accumulator 48 . Via line 92 , on the one hand a pressure compensation can take place, and on the other hand hydraulic accumulator 48 can empty via pressure relief valve 34 in a controlled fashion, so that at all times during the lowering the pressure in hydraulic accumulator 48 is equal to the pressure in hydraulic cylinder 26 . Thus, sudden pressure discharges between hydraulic accumulator 48 and hydraulic cylinder 26 when switching from one operating state into another operating state are avoided. Also, in the exemplary embodiment shown in FIG. 2 , at the beginning of a suspension cycle, i.e., at the beginning of a planned working cycle in which the suspension function is to be used, hydraulic cylinder 26 must be brought into its lowest position so that hydraulic accumulator 48 and hydraulic cylinder 26 are exposed to a common (calibrating) pressure. In the exemplary embodiment shown in FIG. 2 , in addition to the exemplary embodiment shown in FIG. 1 it is possible to switch hydraulic cylinder 26 from the lifting operating state or the neutral position into the lowering operating state, and subsequently again to move directly into the suspension state.
[0057] in order to enable the lowering operating position during the suspension state, here as well the switching position of control device 12 is acquired via sensor 84 . Analogous to the exemplary embodiment shown in FIG. 1 , on the basis of the signal from sensor 84 on-off valves 52 , 68 and control pressure valve 74 are controlled by control unit 86 so as to deactivate the suspension state for the duration of the lowering operating state. If control device 12 is switched from the lowering operating position into a different operating position, via control unit 86 on-off valves 52 , 68 and control pressure valve 74 are again switched and the suspension function is activated. A sudden bouncing up of hydraulic cylinder 26 is prevented by check valve 90 ensuring the same pressure prevails in hydraulic accumulator 48 as in hydraulic cylinder 26 . This function is important for the case in which the load has changed during the lowering of the boom (simultaneous emptying and putting down of a pallet). A temporal sequence of switching processes introduced by control unit 86 can be controlled as necessary using throttles, additional valves, or electronic time delay elements.
[0058] FIG. 3 shows another exemplary embodiment in accordance with the present invention. On-off valves 52 , 60 , 68 are fashioned as pressure-controlled on-off valves 52 , 60 , 68 , and are switched in common via control pressure valve 74 . Temporal sequences are controlled for example via throttles (not shown). The exemplary embodiment shown in FIG. 3 additionally corresponds to the exemplary embodiment shown in FIG. 1 , and such a pressure-controlled situation and design of on-off valves 52 , 60 , 68 is also suitable for the exemplary embodiment shown in FIG. 2 .
[0059] FIG. 4 shows an additional exemplary embodiment corresponding essentially to the exemplary embodiment shown in FIG. 1 . However, pressure compensation device 94 is additionally provided. Pressure compensation device 94 has a line 96 that extends between hydraulic accumulator 48 and hydraulic cylinder 26 , and includes a check valve 98 that closes in the direction of hydraulic cylinder 26 . In addition, a line 99 is provided that extends between hydraulic accumulator 48 and an on-off valve 100 connected to hydraulic tank 20 , and that is provided with a pressure scale 102 . Pressure scale 102 is controlled via pressure lines 104 , 106 on the one hand by the pressure acting in line 96 , and is controlled on the other hand by the pressure acting in line 99 . Depending on the ratio of these two pressures, pressure scale 102 switches into a closed position or into an open position to on-off valve 100 . On-off valve 100 has a closed position oriented in the direction towards hydraulic tank 20 and an open position. In comparison with the exemplary embodiments shown in FIGS. 1 to 3 , here a sensor 82 for determining the position of hydraulic cylinder 26 can be omitted. Hydraulic accumulator 48 is here always charged with at least the highest load pressure of hydraulic cylinder 26 during a particular operating state. Here it is not required to lower hydraulic cylinder 26 before activating the suspension state; rather, the suspension state can be activated at any time after a pressure compensation has taken place between hydraulic accumulator 48 and hydraulic cylinder 26 . Such a pressure compensation can be effected by switching on-off valve 100 so as to open it briefly. This can, for example, take place automatically upon actuation of activation switch 88 for the suspension state by control unit 86 . However, a manual actuation is also contemplated by the present invention. In other respects, the functioning of the hydraulic system shown in FIG. 4 resembles that of the previously described hydraulic system from FIG. 1 .
[0060] With reference to FIG. 5 , another exemplary embodiment is illustrated. The hydraulic system shown in FIG. 5 corresponds essentially in its functioning and design to the exemplary embodiment shown in FIG. 2 . However, in the present embodiment, on-off valve 52 has a leak-free closing position in the direction of control device 12 , and check valve 90 of line 92 is situated parallel to a throttle 107 that is situated in line 92 . Here as well, a sensor 82 that detects the position of the hydraulic cylinder is not necessary, because due to the described location of check valve 90 and throttle 107 and the design of on-off valve 52 , a pressure compensation between hydraulic accumulator 48 and hydraulic cylinder 26 can take place at all times. As a result, when the suspension function is activated hydraulic cylinder 26 cannot lower and also cannot raise or bounce up. The suspension function can, thus, be activated at any time, independent of the position of hydraulic cylinder 26 . As in the previously described exemplary embodiments relating to FIGS. 1 to 4 , in the lowering operating position of control device 12 a deactivation of the suspension function is introduced by control unit 86 for the duration of the lowering operating state, in order to avoid an emptying of hydraulic accumulator 48 . In this exemplary embodiment, it is conceivable to omit check valve 90 , but this will have an adverse effect on the functionality of the pressure compensation. Hydraulic accumulator 48 would then experience a delayed pressure compensation, which would result in some decrease in comfort, but the functionality of the suspension function or of the hydraulic system would not be limited. In the handling of larger loads, a brief lagging or recoil of hydraulic cylinder 26 could occur due to the delayed pressure relief of hydraulic accumulator 48 in the direction of hydraulic cylinder 26 .
[0061] FIG. 6 shows another exemplary embodiment that essentially resembles the exemplary embodiment according to FIG. 2 . The difference is that on-off valve 52 is controlled electrically. In other respects, the manner of functioning in the present embodiment is the same as the manner of functioning of the exemplary embodiment in FIG. 2 . In the present embodiment, control pressure valve 74 is used only to control pressure relief valve 34 . On-off valves 52 , 60 , 68 , and control pressure valve 74 , but in particular on-off valve 60 and control pressure valve 74 , are controlled and monitored by control unit 86 . This is important in order to ensure that control pressure valve 74 closes pressure relief valve 34 , should on-off valve 60 spring into its open position during the suspension state, for example due to an electrical defect (cable breakage, burned-out coil, etc.). Should this not take place, in the suspension state hydraulic cylinder 26 would be capable of lowering in an uncontrolled manner. Such an electrical controlling of on-off valve 60 is also contemplated for the other depicted exemplary embodiments.
[0062] An application for the exemplary embodiments shown in FIGS. 1 to 6 is shown in FIG. 7 . FIG. 7 shows a mobile telescope loader 108 having a boom 110 that can be extended telescopically and that is coupled in pivotable fashion to a frame 109 of telescope loader 108 . A hydraulic cylinder 26 for raising and lowering boom 110 is situated between boom 110 and frame 109 . Further, hydraulic cylinder 26 is coupled in pivotable fashion to a first and to a second bearing point 112 , 114 , the piston rod side being coupled to second bearing point 114 on boom 110 and the piston floor side being coupled to first bearing point 112 on frame 109 . In addition, hydraulic tank 20 , conveying means 18 , and control device 12 are positioned at or in a housing 115 , and are connected to one another via hydraulic lines 14 , 16 , 116 . In addition, in FIG. 7 supply lines 22 , 24 are disposed between control device 12 and hydraulic cylinder 26 . Load holding device 32 , as well as on-off valve 52 and on-off valve 60 , are situated in a common valve module directly on hydraulic cylinder 26 . On-off valve 68 is positioned in housing 115 together with control device 12 . Hydraulic accumulator 48 is, preferably, likewise situated directly on hydraulic cylinder 26 , so that hydraulic line 46 can be fashioned as a rigid connection between the common valve module and hydraulic accumulator 48 , requiring no separate breakage safeguarding device. Control unit 86 generates control or switching signals which switch or control on-off valves 52 , 60 , 68 , as well as control pressure valve 74 , depending on the status of sensors 82 , 84 or activation switch 88 .
[0063] In FIG. 7 , control unit 86 , sensors 82 , 84 , activation switch 88 , control pressure device 70 are not shown. The location of such components is well known in the prior art and can be executed by someone skilled in the art in a known manner.
[0064] Corresponding to the above-described switching positions, hydraulic cylinder 26 can be actuated in such a way that boom 110 can be lifted, held steady, or lowered, and a suspension state can be set or activated for the individual operating states, as described above and illustrated in FIGS. 1 to 6 . When the suspension function is activated, it is ensured that during an excitation, for example due to the traveling mechanism of telescope loader 108 , impact-type accelerations due to a free oscillation of boom 110 are damped, so that traveling comfort is increased, in particular if a work tool 108 is used to pick up and move loads.
[0065] Although the present invention has been described on the basis of some exemplary embodiments, in the light of the foregoing description and the drawings someone skilled in the art will infer a large number of different alternatives, modifications, and variants falling within the scope of the present invention. Thus, for example, the hydraulic system can also be applied to other vehicles, for example to wheel loaders or front-end loaders or to baggers or cranes having components that can be actuated hydraulically and that can be lifted or lowered and in which a suspension is considered desirable.
[0066] The foregoing disclosure is the best mode devised by the inventor for practicing this invention. It is apparent, however, that methods incorporating modifications and variations will be obvious to one skilled in the art of motor vehicle clutches and lubrication thereof. Inasmuch as the foregoing disclosure is intended to enable one skilled in the pertinent art to practice the instant invention, it should not be construed to be limited, thereby but should be construed to include such aforementioned obvious variations and be limited only by the spirit and scope of the following claims.
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A hydraulic system for a suspension system is disclosed. The system has a hydraulic cylinder, a hydraulic tank, a conveying means, a hydraulic accumulator, a control device, a load holding device disposed between the hydraulic accumulator and the hydraulic cylinder, and an on-off valve disposed between the hydraulic accumulator and the control device. In order to provide a suspension function for the hydraulic cylinder while simultaneously ensuring safeguarding of the hydraulic cylinder and of the hydraulic accumulator against a pressure drop in the case of a tube break, the present invention provides a system that controls the on-off valve and the load holding device synchronously through a control pressure device, such that when the suspension function is activated the load holding device is opened and the on-off valve is closed.
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BACKGROUND OF THE INVENTION
1. Technical Field
[0001] The present invention relates to a mounting device and more particularly to an adaptable lock mounting device configured to be mounted with a lock.
2. Description of Related Art
[0002] There are many auxiliary locks for use with vehicles, including, for example, folding locks and curved-sectioned locks (as disclosed in Taiwan Patent No. 229678, entitled “transformable sectioned lock with curved members”). Related products include the “lock mounting device” disclosed in Taiwan Patent No. M509758.
[0003] The afore-cited lock mounting device has a coupling member of a single configuration and therefore is applicable only to a specific portion of a vehicle frame or to vehicle frames of a particular specification. In other words, the lock mounting device has limited applications and lacks flexibility in terms of mounting. From a consumer's point of view, such a product is inconvenient to use; from a manufacturer's perspective, different molds must be designed in order to make products of different specifications, which leads to a high production cost and hinders reduction in product price.
BRIEF SUMMARY OF THE INVENTION
[0004] In view of the above, the inventor of the present invention provides an adaptable lock mounting device featuring high adaptability. The adaptable lock mounting device is configured to be mounted with a lock and couple with a vehicle frame, wherein the lock includes a lock cylinder and a keyhole in the lock cylinder. The adaptable lock mounting device includes a coupling base, a mounting base, and a fixing member. The coupling base includes a first coupling portion and a second coupling portion. The first coupling portion is a tubular portion configured to be fixedly mounted around a tubular portion of the vehicle frame. The mounting base includes a lock mounting portion and a linking portion. The lock mounting portion includes a fitting portion and an aperture in the fitting portion. The fitting portion is configured to be fitted around the lock cylinder such that the aperture corresponds to the keyhole. The linking portion is one of a sliding block and a corresponding sliding sleeve to be fitted around the sliding block, and the second coupling portion of the coupling base is the other of the sliding block and the corresponding sliding sleeve, in order for the mounting base to couple with the coupling base via the linking portion in a detachable manner. The fixing member is configured to connect the mounting base and the coupling base in a detachable manner.
[0005] Preferably, the second coupling portion is the sliding block while the linking portion is the sliding sleeve.
[0006] Preferably, the coupling base has a first coupling hole, the mounting base has a second coupling hole corresponding to the first coupling hole, and the fixing member is configured to pass through the first coupling hole and the second coupling hole.
[0007] Preferably, the lock mounting portion includes two position-limiting portions and a lateral portion. The position-limiting portions are located on two sides of the lateral portion respectively, and the fitting portion is located at the lateral portion, such that a mounting space and an opening are defined between the position-limiting portions and the lateral portion. The mounting space is configured to be mounted with the lock. The opening corresponds to the lateral portion and is in communication with the mounting space. The direction in which the lateral portion and the opening extend is defined as a withdrawal direction. It is also preferable that a position-limiting member is movably connected to the lock mounting portion and corresponds to the opening.
[0008] Preferably, the position-limiting member has one end pivotally connected to the mounting base and another end corresponding to the lock.
[0009] The present invention also provides an adaptable lock mounting device configured to couple with a vehicle frame and including an assembly base in addition to the aforesaid mounting base and fixing member. The assembly base includes a third coupling portion and a fourth coupling portion. The third coupling portion has a plurality of coupling holes, each allowing passage of a coupling member in order for the coupling member to be locked to the vehicle frame. The linking portion of the mounting base is one of a sliding block and a corresponding sliding sleeve to be fitted around the sliding block, and the fourth coupling portion of the assembly base is the other of the sliding block and the corresponding sliding sleeve, in order for the mounting base to couple with the assembly base via the linking portion in a detachable manner. The fixing member is configured to connect the mounting base and the assembly base in a detachable manner.
[0010] Preferably, the fourth coupling portion of the assembly base is the sliding block while the linking portion is the sliding sleeve.
[0011] Preferably, the assembly base has a first coupling hole, the mounting base has a second coupling hole corresponding to the first coupling hole, and the fixing member is configured to pass through the first coupling hole and the second coupling hole.
[0012] The foregoing technical features have the following advantageous effects:
[0013] 1. The lock mounting device features adaptability and flexibility in terms of assembly because the mounting base can be assembled to the coupling base or the assembly base as needed. In addition, the sliding block and the corresponding sliding sleeve (or sliding groove) facilitate assembly and detachment.
[0014] 2. Once the mounting base is detachably assembled to the coupling base or the assembly base, the fixing member can be passed through the first coupling hole and the second coupling hole to position the mounting base effectively and prevent the mounting base from getting loose.
[0015] 3. The position-limiting member serves to block the lock so that the lock will not separate from the mounting base.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0016] FIG. 1 is an exploded perspective view of an embodiment of the present invention;
[0017] FIG. 1A is a perspective view of the mounting base in FIG. 1 but is taken from a different viewpoint;
[0018] FIG. 1B is a plan view of the mounting base in FIG. 1A ;
[0019] FIG. 2 is a perspective view showing the embodiment in FIG. 1 mounted on a vehicle frame via the coupling base;
[0020] FIG. 3A is an exploded sectional top view showing how the embodiment in FIG. 1 is mounted to a vehicle frame via the coupling base;
[0021] FIG. 3B is a sectional top view showing the embodiment in FIG. 1 mounted on a vehicle frame via the coupling base;
[0022] FIG. 4A is an exploded sectional side view showing how the embodiment in FIG. 1 is mounted to a vehicle frame via the coupling base;
[0023] FIG. 4B is a sectional side view showing the embodiment in FIG. 1 mounted on a vehicle frame via the coupling base;
[0024] FIG. 5 is a perspective view showing the embodiment in FIG. 1 mounted on a vehicle frame via the assembly base;
[0025] FIG. 6 is an exploded perspective view showing how the embodiment in FIG. 1 is mounted to a vehicle frame via the assembly base;
[0026] FIG. 7A is an exploded sectional top view showing how the embodiment in FIG. 1 is mounted to a vehicle frame via the assembly base;
[0027] FIG. 7B is a sectional top view showing the embodiment in FIG. 1 mounted on a vehicle frame via the assembly base;
[0028] FIG. 8A is an exploded sectional side view showing how the embodiment in FIG. 1 is mounted to a vehicle frame via the assembly base; and
[0029] FIG. 8B is a sectional side view showing the embodiment in FIG. 1 mounted on a vehicle frame via the assembly base.
DETAILED DESCRIPTION OF THE INVENTION
[0030] The present invention incorporates the foregoing technical features into an adaptable lock mounting device, whose major effects are detailed as follows.
[0031] Referring to FIG. 1 , the adaptable lock mounting device in an embodiment of the present invention is configured to be mounted with a lock A and couple with a vehicle frame B. The lock A includes a lock cylinder A 1 and a keyhole A 2 in the lock cylinder A 1 . The adaptable lock mounting device includes a coupling base 1 , an assembly base 2 , a mounting base 3 , and a fixing member 4 .
[0032] The coupling base 1 includes a first coupling portion 11 and a second coupling portion 12 . The first coupling portion 11 is a tubular portion configured to be fixedly mounted around a tubular portion of the vehicle frame B. The assembly base 2 includes a third coupling portion 21 and a fourth coupling portion 22 . The third coupling portion 21 has a plurality of coupling holes 211 . A plurality of coupling members 212 can pass through the coupling holes 211 respectively and be fixed to the vehicle frame B. In this embodiment, the second coupling portion 12 and the fourth coupling portion 22 are sliding blocks but are not necessarily so; they may be sliding sleeves instead.
[0033] With continued reference to FIG. 1 , the mounting base 3 includes a lock mounting portion 31 and a linking portion 32 . The lock mounting portion 31 includes a fitting portion 311 and an aperture 312 in the fitting portion 311 . The fitting portion 311 is configured to be fitted around the lock cylinder A 1 such that the aperture 312 corresponds to the keyhole A 2 . More specifically, referring to FIG. 1 and FIG. 1A , the lock mounting portion 31 further includes two position-limiting portions 313 and a lateral portion 314 . The position-limiting portions 313 tilt toward each other and are located on two opposite sides of the lateral portion 314 respectively. Also, the fitting portion 311 is located at the lateral portion 314 . Consequently, a mounting space 315 and an opening 316 are defined between the position-limiting portions 313 and the lateral portion 314 . The mounting space 315 is configured to be mounted with the lock A. The opening 316 corresponds to the lateral portion 314 and communicates with the mounting space 315 . The direction in which the lateral portion 314 and the opening 316 extend is defined as a withdrawal direction. Preferably, a position-limiting member 5 is further included, is movably (e.g., pivotally) connected to the lock mounting portion 31 , and corresponds to the opening 316 in order to block the lock A.
[0034] As shown in FIG. 1 and FIG. 1B , the linking portion 32 in this embodiment includes a sliding sleeve 320 but may include a sliding block instead. In the latter case, the second coupling portion 12 and the fourth coupling portion 22 should be configured as sliding sleeves corresponding to the sliding block. More specifically, the sliding sleeve 320 includes a pair of sidewalls 321 and a connecting portion 322 connecting the sidewalls 321 such that a sliding groove 323 is defined between the sidewalls 321 and the connecting portion 322 . Each sidewall 321 may be further extended with an engaging portion 324 opposite the connecting portion 322 in order to block the second coupling portion 12 or fourth coupling portion 22 in the sliding groove 323 . Preferably, the sidewalls 321 have a first coupling hole 3210 , the coupling base 1 further includes a positioning portion 13 and a second coupling hole 131 , and the assembly base 2 further includes a positioning portion 23 and a second coupling hole 231 . The positioning portions 13 and 23 correspond to the sidewalls 321 . The second coupling holes 131 and 231 are located in the positioning portions 13 and 23 respectively so that the fixing member 4 can pass through the first coupling hole 3210 and the second coupling hole 131 or 231 . It should be pointed out that the first coupling hole 3210 may be directly provided in the sliding sleeve 320 , and that the second coupling holes 131 and 231 may be directly provided in the second coupling portion 12 and the fourth coupling portion 22 respectively. With either arrangement, the mounting base 3 can be fixed to the coupling base 1 or the assembly base 2 just as well.
[0035] In terms of use, referring to FIG. 2 , a user may mount the mounting base 3 to a cylindrical bar B 1 of the vehicle frame B as follows. The mounting process begins by fixedly mounting the first coupling portion 11 of the coupling base 1 around the bar B 1 , as shown in FIG. 3A and FIG. 3B . Then, the sliding groove 323 of the sliding sleeve 320 of the mounting base 3 is mated with the second coupling portion 12 of the coupling base 1 in a sliding manner. As a result, referring to FIG. 4A and FIG. 4B , two opposite sides 121 of the second coupling portion 12 (which is implemented as a sliding block in this embodiment) correspond to the sidewalls 321 of the sliding sleeve 320 respectively, and the second coupling portion 12 is blocked by the engaging portions 324 of the linking portion 32 . Moreover, the first coupling hole 3210 of the mounting base 3 is aligned with the second coupling hole 131 of the coupling base 1 , allowing the fixing member 4 (e.g., a threaded locking member or a pin) to pass through the first coupling hole 3210 and the second coupling hole 131 , thereby fixing the mounting base 3 to the coupling base 1 securely.
[0036] Alternatively, referring to FIG. 5 and FIG. 6 , the user may mount the mounting base 3 to a non-cylindrical bar B 2 of the vehicle frame B and then place the lock A into the mounting space 315 of the mounting base 3 , with the lock cylinder A 1 fitted in the fitting portion 311 of the mounting base 3 . This mounting process starts by mounting the third coupling portion 21 of the assembly base 2 to the bar B 2 via the coupling members 212 (e.g., locking and connecting members). After that, referring to FIG. 7A and FIG. 7B , the sliding groove 323 of the sliding sleeve 320 of the mounting base 3 is mated with the fourth coupling portion 22 (which is implemented as a sliding block in this embodiment) of the assembly base 2 in a sliding manner. Consequently, as shown in FIG. 8A and FIG. 8B , two opposite sides 121 of the fourth coupling portion 22 correspond to the sidewalls 321 of the sliding sleeve 320 respectively, and the fourth coupling portion 22 is blocked by the engaging portions 324 of the linking portion 32 . Moreover, the first coupling hole 3210 of the mounting base 3 is aligned with the second coupling hole 231 of the assembly base 2 , allowing the fixing member 4 (e.g., a threaded locking member or a pin) to pass through the first coupling hole 3210 and the second coupling hole 231 , thereby fixing the mounting base 3 to the assembly base 2 securely.
[0037] The embodiment described above is but a preferred one of the present invention and is not intended to be restrictive of the scope of the invention. All simple equivalent variations and modifications made according to the appended claims and the disclosure of this specification should fall within the scope of the invention.
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An adaptable lock mounting device featuring adaptability and flexibility of use is configured to couple with a vehicle frame and includes a mounting base to detachably couple with a coupling base or an assembly base as appropriate, wherein the coupling base is different from the assembly base. A portion of the mounting base is one of a sliding block and a corresponding sliding sleeve to be fitted around the sliding block, while each of a portion of the coupling base and a portion of the assembly base is the other of the sliding block and the corresponding sliding sleeve.
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FIELD OF THE INVENTION
[0001] This invention relates to tools and in particular a tool having a slidable bar adapted to allow the tool to function as both a clamp and a spreader jack.
BACKGROUND OF THE INVENTION
[0002] Hand tools adapted to clamp, grip or otherwise hold together pieces of wood, steel, or other materials for temporary or permanent connection are known.
[0003] Prior art C clamps have many disadvantages. Prior art C clamps often employ a screw mechanism to generate the clamping forces. Such devices are slow and require both hands to operate. They also have limited displacement which in turn limits the size and shape of the workpiece which can be clamped. While it is know to simply increase the size of a clamp to adapt it to fit a larger workpiece, such clamps are heavy and difficult to maneuver. Further, such prior art clamps are not readily adapted to be used as a spreader jack nor do such clamps permit clamping at the inside apex angle of the workpiece.
[0004] Prior art clamps are also limited in that the maximum span of the clamp is often fixed and limited and the trigger mechanism which advances one of the jaw bars is not reversible and/or is difficult to reassemble following disassembly.
[0005] Each of U.S. Pat. No. 4,893,801 to Flinn; U.S. Pat. No. 5,005,449 to Sorensen et al.; U.S. Pat. No. 5,009,134 to Sorensen et al.; U.S. Pat. No. 5,170,682 to Sorensen et al. and U.S. Pat. No. 5,222,420 to Sorensen et al. disclose hand held clamps having a fixed jaw secured to a hand grip and a movable jaw secured to one end of a single slidable bar member adapted to extend through the hand grip. Sorensen et al. '682 discloses a tool having the capacity to readily convert from a clamp to a spreader jack; however, in order to reverse the face of the movable jaw a force in excess of 200 pounds must be applied to the pins in order to facilitate removal. Further, the use of a coil spring in the trigger mechanism of the handle/bar holder will cause the gripping plate and other elements in the trigger mechanism to fall out of alignment as the bar is withdrawn from the handle and necessarily renders reassembly difficult. U.S. Pat. No. 5,009,134 to Sorensen et al. also mandates the removal and reversal of one of the jaws in order to adapt the device for use as a spreader jack. The hand held clamp of Flinn discloses two parallel bars, however one of the bars is fixed.
OBJECT AND SUMMARY OF THE INVENTION
[0006] It is an object of this invention to provide a tool adapted to be easily converted so as to function as a clamp or as a spreader jack.
[0007] Another object is to provide a trigger mechanism for a tool handle that may be rotated 180 degrees to adapt the tool for purposes of offset jacking, for example, when jacking a double hung window.
[0008] A further object is to provide a tool where the at least two slidable bars are adapted to provide a so-called C clamp (FIG. 5) having a greatly expanded capacity to receive the workpiece to be clamped; namely, the entire lengths of each of the slidable bars are separately and adjustably received within the bar holder to thereby increase clamping displacement or volume and/or allow clamping of unusual shapes such as an L or T shaped workpiece and where the clamping force must be applied near the inside apex of the workpiece angle and/or the clamp must reach past an intervening leg of the workpiece angle.
[0009] Another object is to provide a tool having an improved handle mechanism so that the slidable bars received in the handles may readily be reversed without the need to apply a great deal of force and effort as is required during reversal of the prior art devices and further, will not result in the various individual trigger mechanism elements falling apart as is the case in the prior art devices.
[0010] Another object of this invention is to provide a tool having both expansion and compression capability without the need for removal and reversal of a jaw member.
[0011] Another object of the present invention is to provide a tool adapted to permit removal of one of the bars yet still allow the tool to function as a clamp or spreader jack.
[0012] A further object of this invention is to provide an adjustable tool readily adapted to receive one or more pieces of work material.
[0013] Still a further object of this invention is to provide a tool having sufficient clearance for grasping the work at different points or locations.
[0014] A further object of this invention is to provide a work tool having four separate jaws.
[0015] A still further object of the invention is to provide a tool having a readily reversible feature due to the use of a leaf spring in the trigger mechanism that allows the slidable bars to be easily removed from the handle and reversed without the need for tools and without causing the trigger mechanism parts to become displace and therefore difficult to reassemble as is the case with the prior art devices.
[0016] Another object of the invention is to provide a tool having a trigger mechanism in the handle which includes a leaf spring adapted to remain in a working position during disassembly of the trigger mechanism due to the provision of a curved surface at one end of the leaf spring which retains the gripping plate in place.
[0017] Still another object of the present invention is to provide a tool having a auxiliary jaw to enable the device to operate as a true C clamp and thereby permit clamping beyond flanges or other obstructions.
[0018] In addition, the present device provides a tool having a slidable bar, one end of which includes a standing jaw-comprising a pair of opposed face plates at one end thereof so that the tool according to the present invention may be readily converted from a clamp and into a spreader jack.
[0019] In summary, the present invention relates to a work tool for clamping, expanding and/or pushing away of the work material, either temporarily or permanently.
[0020] These and other objects will be apparent from the following description and the drawings which are described as follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] [0021]FIG. 1 is a perspective view of the work tool according to the present invention when in a compression position and showing the work and pin holes in phantom lines;
[0022] [0022]FIG. 2 is a perspective view of the work tool according to the present invention when in the expansion position and showing the work shown in phantom lines;
[0023] [0023]FIG. 3 is an enlarged, fragmentary side elevation view of the work tool with the trigger mechanism in a release position;
[0024] [0024]FIG. 3A is a perspective view of the U-shaped spring shown in FIG. 3;
[0025] [0025]FIG. 4 is an enlarged, fragmentary side elevation view of the work tool shown in FIG. 3 with the trigger in the activation position;
[0026] [0026]FIG. 5 is a side elevation view of a work tool according to the present invention and with the work shown in phantom lines;
[0027] [0027]FIG. 6 is an exploded, perspective view of the work tool shown in FIG. 5; and
[0028] [0028]FIG. 7 is a sectional view taken along lines 7 - 7 in FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] Each of the figures illustrate the work tool T according to the present invention. The tool T includes a handle 2 having an upper bar holder 4 and a lower bar holder 6 each of which are adapted to adjustably receive a separate bar which will be further described below. The handle 2 is provided with a trigger 8 and a release trigger mechanism 10 .
[0030] As best shown in each of FIGS. 3, 4 and 7 , the trigger 8 is provided with a pivot portion 12 adapted to pivot in housing 14 of the handle 2 . Within the housing 14 is provided a U-shaped spring 16 . Spring 16 is best shown in FIG. 3A. Spring 16 is shown to be biased against a gripping plate 18 positioned between spring 16 and the trigger 8 . As can be seen in each of FIGS. 3 and 4, the trigger 8 operates and is moveable in recess 20 of handle 2 . FIG. 3 shows the trigger 8 in a forward position prior to actuation. FIG. 4 shows the trigger 8 during operation or in the actuated position. The trigger 8 is shown to be snap fit into the housing 14 and is of a yoke or design fixing around lower bar holder 6 . As is apparent, a spring design other than that as shown in the drawings is within the scope of the present invention so long as the trigger 8 functions in the manner as described below. Further, an actuation device other than a spring is within the scope of the present invention so long as the actuation device selected permits the device to operate in the manner described below.
[0031] The housing 14 , as best shown in FIGS. 3 and 4, includes the release trigger mechanism 10 which pivots in the hook portion 22 of the housing 14 and is secured by a pivot pin 23 . The release trigger mechanism 10 is best shown in FIG. 6 and includes a window opening 24 .
[0032] Turning to FIG. 6, a lock pin 26 is shown to extend through an opening 28 in the handle 2 and is secured by a nut or lock washer 30 . Lower bar 32 includes work a engaging device 34 having an expansion or face plate 36 and a compression or face plate 38 and is adapted to be slidingly received in lower bar holder 6 and through window 24 of the release trigger mechanism 10 . Upper bar 40 is adapted to be slidingly received in upper bar holder 4 and includes face plate 42 which may be used for compression and/or expansion work. A locking pin 26 is adapted to selectively engage lock positioning notches 44 of upper bar 40 . It is understood that instead of notches 44 , pin holes 46 (FIG. 1) may be substituted on upper bar 40 to lock or otherwise fix the position of upper bar 40 within bar holder 4 . If pin holes 46 are used, the pin 26 is mounted in handle 2 so as to align with pin holes 46 .
[0033] As is apparent, the device as set forth above may be constructed from a variety of materials depending upon design considerations. In particular, the clamping or jacking forces of the device are directly related to the nature of the construction materials used. For example, the use of high strength steels will yield a tool having high durability and strength and which is readily adapted to hold or spread heavy metal object whereas the use of plastic materials will provide a tool having light weight for ease of handling and which may be readily adapted for use with wooden or plastic work materials. In the alternative, a combination of different materials may be used. For example, the upper and lower bars as well as the spring may be constructed from steel or other another metal material for purposes of durability and strength whereas the remaining parts may be constructed from injection molded reinforced plastic to reduce the weight of the device and overall manufacturing costs.
[0034] The tool according to the present invention operates in the following manner. When the trigger 8 is actuated, the gripping plate 18 moves to the right, from a position shown in FIG. 3 to the position shown in FIG. 4, compressing spring 16 and thereby causing the bar 32 to move incrementally in the direction of the arrow on bar 32 as best seen in FIG. 4. Release of the trigger 8 will set the trigger 8 in position for another incremental move permitting the bar 32 to be moved in relation to the bar 40 . Bar 40 is initially positioned by sliding the bar 40 in the bar holder 4 and then locking in position with the pin 26 engaging a notch 44 or hole 46 to lock the bar 40 in position relative to the bar 32 . Depending upon the position of the bars 32 and 40 in the handle 2 , the face plates 36 and 42 will face each other for clamping the work W as shown in each of FIGS. 1 and 5. The work engaging device 34 with the face 38 when positioned for expansion, as shown in FIG. 2, is reversed in the handle 2 so that it will operate in the expansion mode for engaging with the work W. The work engaging device 34 is fixed on the bar 32 and need not be removed therefrom in order to use it as expansion or compression mechanism. Only bar 32 need be removed and reversed in the handle 2 for selectively adapting the device for either compression or expansion mode. Release trigger 10 is designed to lock bar 32 from movement in the direction opposite to the movement of the bar 32 when actuated by trigger 8 . When the release trigger mechanism 10 is operated, the bar 32 can be slipped in lower bar holder 6 for rapid initial adjustment.
[0035] While this invention has been described as having a preferred design, it is understood that it is capable of further modification, uses and/or adaptations following in general the principle of the invention and including such departures from the present disclosure as come within known or customary practice in the art to which the invention pertains, and as may be applied to the essential features set forth, and fall within the scope of the invention or the limits of the appended claims.
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A tool for selectively compressing and expanding work, the tool comprising a handle including bar holders and at least two slidable bars having work engaging surfaces at ends thereof both of which are slidably received in a separate one of the bar holders and both being adapted to be selectively fixed therein whereby at least one of the slidable bars is adapted to be reversibly received in one of the bar holders of the handle.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a material for protecting wire harnesses and a wire harness comprising such protecting material. More particularly, the invention relates to a wire harness-protecting material suitable for protecting the external periphery of a bundle of electrical wires or cables in wire harnesses used for wiring vehicles or electrical appliances or products.
[0003] The wire harness comprises a bundle of electrical cables, each of which, in turn, comprises one or several conductor element(s) coated e.g. with a polyolefin-type insulating resin material. The polyolefin-type insulating resin material of the invention contains no halogen atom, or its halogen content is at least lower than that of vinyl chloride resin. Such an electrical cable is called “halogen-free insulated electrical cable” (HF electrical cable), and a bundle of such electrical cables is referred to as a “HF-type cable bundle”. When part of HF electrical cables contained in a single cable bundle is replaced by electrical cables in which the conductor element(s) is/are coated with polyvinyl chloride resin (PVC-type electrical cables), the bundle is called “mixed cable bundle”. The wire harness of the invention is prepared by wrapping such a bundle with a harness-protecting material composed of a tape base (or tape base material) and an adhesive (or adhesive layer).
[0004] 2. Description of Background Information
[0005] Recently, higher performance and functionality have been sought after, especially for vehicles and electrical products. To this end, many items of electronic equipment have been installed in vehicles, electrical products and the like. Further, for good and precise functioning, these vehicles or electrical products employ a plurality of electrical wires or cables for their internal wiring.
[0006] Generally, the plurality of electrical cables are assembled into an electrical cable bundle, which is then used as what is referred to as a “wire harness”. The wire harness is also referred to as “assembled electrical cables”, in which a plurality of electrical cables are assembled beforehand into ready-to-wire configurations. In other words, the necessary branching(s) and connector-mounting(s) at cable ends, for instance, are prepared beforehand, and the bundle of electrical cables is then wrapped with various forms of harness-protecting materials such as tapes, tubes and sheets.
[0007] The electrical cable used in the wire harness usually comprises one or several conductor element(s) made of e.g. copper, which is/are coated with a vinyl chloride resin (such as polyvinyl chloride), supplemented with additives e.g. a plasticizer and a heat stabilizer so as to make the cable flexible and formable (PVC-type electrical cable).
[0008] A harness-protecting material may be in the form of an adhesive tape, which itself comprises a tape base (material) made of a vinyl chloride resin e.g. polyvinyl chloride. A surface of the tape base is then painted (coated) with an adhesive (layer) which comprises natural or synthetic rubber etc. supplemented with an adhesive adjuvant, a plasticizer etc. The adhesive tape obtained is referred to hereinafter as a PVC-type adhesive tape.
[0009] However, the commonly used vinyl chloride resin contains halogen atoms in its molecular structure whereupon, when vehicles or electrical appliances are burnt e.g. to be discarded or processed as waste, toxic halogen gas is liberated in the air and pollutes the environment.
[0010] Accordingly, the vinyl chloride resin used in PVC-type electrical cables and PVC-type adhesive tapes is being replaced by a resin containing no halogen, as part of environment protection measures.
[0011] The replacement resins include, for example, a halogen-free flame retardant olefin resin, in which an olefin resin is supplemented with a flame retardant, a copper damage inhibitor, anti-oxidizing agent and the like.
[0012] Accordingly, as electrical cables for wire harnesses, PVC-type electrical cables may be used alone, or together with HF-type electrical cables, in which conductor elements made e.g. of copper are coated with a halogen-free resin. Furthermore, HF-type electrical cables may also be used alone.
[0013] Likewise, in the tape-shaped harness-protecting materials, PVC-type adhesive tapes may be used alone, or together with HP-type adhesive tapes, in which the base material is replaced by a HF-type resin. Furthermore, PVC-type adhesive tapes may also be used alone.
[0014] The wire harnesses used in vehicles are subjected to extremely severe environments surrounding the motor, so that heat- and oxidation-resistant qualities of the harnesses become very important criteria.
[0015] In such a context, wire harnesses have been prepared by wrapping with a PVC-type adhesive tape a bundle of electrical cables composed solely of HF-type electrical cables and a bundle of the latter mixed with PVC-type electrical cables. Hot oxidation tests effected on those harnesses revealed that the heat- and oxidation-resistant qualities of HF-type electrical cables in each harness are considerably lower than those of an individual HF-type electrical cable.
[0016] Further, wire harnesses have been prepared by wrapping with a HF-type adhesive tape a bundle of electrical cables composed solely of HF-type electrical cables and a bundle of the latter mixed with PVC-type electrical cables. Likewise, hot oxidation tests effected on those harnesses revealed that the heat- and oxidation-resistant qualities of HF-type electrical cables in each harness are considerably lower than those of an individual HF-type electrical cable.
[0017] The inventors have then investigated on the deterioration of the electrical cables contained in a wire harness, when various types of cable bundle are wrapped with a tape-shaped harness-protecting material.
[0018] As already mentioned, the tape-shaped harness-protecting material has a structure in which a surface of the tape base is painted with an adhesive. When this harness-protecting material is wrapped around a cable bundle of one kind or another, the adhesive is placed in direct contact with the cable bundles. As a result, the adhesive adjuvants, plasticizers etc. contained in the adhesive penetrate into the coatings of HF-type electrical wires and are diffused therein.
[0019] The diffused adhesive adjuvants, plasticizers etc. act on the conductor element, e.g. copper, of the HF-type electrical cables, and create copper ions having a catalytic effect.
[0020] The copper ions formed in the coatings of an individual HF-type electrical wire are trapped by copper damage inhibitors already existing in the coatings, and form a chelate compound, thus preventing catalytic activities. However, as the ionisation of copper is accelerated by the adhesive adjuvants, plasticizers etc., the copper damage inhibitors previously added to the HF-type wire coatings are consumed more than expected, and become deficient.
[0021] Then, the copper ions formed in excess of the copper damage inhibitors' capacity can no longer be stabilized as chelate compounds. The catalytically active copper ions thus cut off the chemical bonds in the coating material (e.g. HF-type resins), and accelerate its degradation. This phenomenon is called “copper damage”. It causes the hot oxidation-resistant capability of the HF-type electrical wires contained in a wire harness to be considerably lower than that of an individual HF-type electrical wire.
[0022] Further, the anti-oxidizing agents added beforehand to the coatings of the HF-type electrical wires are dissolved and extracted by the adhesive adjuvants, plasticizers etc. which have moved to become present in the coating materials. Then, the adhesive adjuvants, plasticizers etc. containing the anti-oxidizing agents move again into the wire harness-protecting materials. Accordingly, the anti-oxidizing agents in the coatings diminish faster than their expected time-dependent reduction. The hot oxidation-resistant capacity of the HF-type electrical wires in a wire harness is thus considerably lower than that of an individual HF-type electrical wire.
[0023] Accordingly, in the tape-shaped harness-protecting materials, the adhesive adjuvants, plasticizers and other coating-noxious, low molecular-weight compounds (hereafter referred to as adhesive-side deterioration accelerators) are present in the adhesive which is placed in direct contact with the wire bundle surface, and greatly contribute to the deterioration of the electrical cables.
[0024] When, as in the case of PVC-type adhesive tapes, the tape base contains plasticizers and the like, the plasticizers and other coating-noxious low-molecular compounds (hereafter referred to as tape base-side deterioration accelerators) move into the wire coatings through the adhesive, and may cause a similar deterioration.
[0025] The present invention therefore has as a first main object to provide a tape-shaped harness-protecting material which substantially suppresses damage to electrical cables, in particular those coated with halogen-free resins, contained in a wire bundle for a wire harness. This object is attained by substantially suppressing copper damage caused at least by the migration of adhesive adjuvants, or by inhibiting copper damage and the decrease in anti-oxidizing agents contained in the coatings caused by the migration of adhesive-side deterioration accelerators and the tape base-side deterioration accelerators. Another object of the invention is to provide a wire harness implementing such a harness protecting material.
[0026] As mentioned above, a wire harness installed in automobiles or other vehicles is called “assembled electrical wires”. Electrical cables having an appropriate specificity and size are selected, cut off and assembled to make a cable bundle. The bundle is then passed through a tube, or wrapped with a sheet and the like, and bundled by taping. Subsequently, various kinds of electrical parts are attached to the bundle and assembled to constitute an entity. An electrical cable is commonly prepared by grouping several conductor wires and covering them with a PVC resin coating. The conductor wire is usually made of annealed soft copper wire, or a tin-plated soft copper wire.
[0027] The tape commonly used (PVC tape) comprises a tape base composed of a PVC resin which is mixed with a plasticizer etc., and an adhesive painted on the base material. This adhesive comprises a base material made of low-molecular weight rubber e.g. SBR and NR, which is supplemented with an adhesive adjuvant (rosin-type resin) and a plasticizer (DOP, DINP, DBP). Other than tapes, common types of harness-protecting material include, for instance, a PVC tube and PVC sheet, in which PVC resin is supplemented with a plasticizer and the like. In other words, the PVC resin is predominantly used not only as insulator coatings for electrical cables, but also as cable- or harness-protecting materials (tapes, tubes, sheets).
[0028] However, the PVC electrical cables widely used as insulated cables raise environmental problems, and searches for replacement products have been undertaken. There has thus been proposed a HF-type electrical cable, in which polyolefin is mixed with a large quantity of inorganic filler as flame retardant.
[0029] In order to test the hot oxidizing tendency of wire harnesses, a HF-type plain cable bundle is mounted with a PVC tube or a PVC sheet, and both ends of PVC tube or sheet are bundled with an adhesive-painted PVC tape to form a wire harness. A mixed cable bundle is likewise processed to form another wire harness (FIGS. 2 and 3). These wire harnesses are then subjected to hot oxidation tests.
[0030] As a result, it became clear that the wire harness made of a mixed cable bundle shows a much worse hot oxidizing property than the wire harness made of a plain HF cable bundle. The mixed cable bundle is then analysed to detect which part of the bundle is most affected. When a bundled portion (designated A) in which the adhesive-painted tape is used and non-bundled portion (designated B) are compared, the former of the mixed cable bundles tends to exhibit more cracks and deterioration (FIGS. 2 and 3).
[0031] After repeated experiments effected by the present inventors on hot oxidizing behaviour, it is now understood that the different behaviour between the above two types of bundles may stem from the phenomenon of migration of the plasticizer contained in the PVC tube or sheet, as well as the adhesive adjuvants, plasticizers or low-molecular compounds contained in the adhesive-painted PVC tape.
[0032] Firstly, a HF-type electrical cable contains a given quantity of anti-oxidizing agent from the beginning. This anti-oxidizing agent is dissolved in plasticizers and adhesive adjuvants, when the latter migrate to the cable from a PVC tape, tube or sheet (PVC-type protecting material). The plasticizers and the adhesive adjuvants then “carry” the anti-oxidizing agent out from the HF-type electrical cable, and go back to the PVC-type protecting material where the concentration gradient of the anti-oxidizing agent is lower. Accordingly, the HF-type electrical cable begins to lack the anti-oxidizing agent, and its oxidation is accelerated. To avoid this, the diffusion of anti-oxidizing agent must be stopped, e.g. by blocking the movement of the carriers such as plasticizers and adhesive adjuvants.
[0033] Secondly, when the plasticizers and adhesive adjuvants contained in the PVC-type protecting material move into the HF-type electrical cable, they react with copper wires in the cable and accelerate the ionisation of copper. This phenomenon causes copper damage, i.e. the copper ions thus formed act as catalysers, cut off the chemical bonds in the polymers used in cable coatings, and deteriorate the cable coatings. The ionisation of copper must therefore be stopped, e.g. by limiting the migration of the plasticizers and adhesive adjuvants which react with copper.
[0034] Thirdly, as mentioned above, the plasticizers and adhesive adjuvants in the PVC-type protecting material move into the HF-type electrical cable, react with copper wires and accelerate the ionisation of copper. Accordingly, the copper damage inhibitor, which is included in the HF-type electrical cable in a given quantity from the beginning, is consumed in excess. Such a copper damage inhibitor serves to stabilize the copper ions generated by the reaction of copper wires with water contained in the air which penetrates into the HF-type electrical cable through the PVC-type protecting material. However, it is not intended to stabilize the copper ions formed under the effect of plasticizers and adhesive adjuvants. The consumption of copper damage inhibitor must therefore be reduced, e.g. by inhibiting the ionisation of copper, i.e. preventing the migration of the plasticizers and adhesive adjuvants.
[0035] Fourthly, as explained above, the copper damage inhibitor contained in the HF-type electrical cable is dissolved in the plasticizers and adhesive adjuvants, when they migrate from the PVC-type protecting material to the HF-type electrical cable. The plasticizers and the adhesive adjuvants then “carry” the copper damage inhibitor out from the HF-type electrical cable, and go back to the PVC-type protecting material where the concentration gradient of the copper damage inhibitor is lower. The copper damage inhibitor is then consumed for stabilizing the copper ions generated by water in the air under the influence of plasticizers and adhesive adjuvants, on the one hand, and, on the other, is carried on the plasticizers and adhesive adjuvants and diffused from the HF-type electrical cable into the PVC-type protecting material. The amount of copper damage inhibitor decreases thus in a synergetic manner, and the oxidation of the HF-type electrical cable is further accentuated. The diffusion and decrease of the copper damage inhobotor must thus be prevented, e.g. by preventing the migration of the carriers such as the plasticizers and adhesive adjuvants.
[0036] As an example, the cable bundles are wrapped with a tube or sheet made of HF-type polyethylene or polypropylene (HF-type protecting material), and closed by an adhesive-painted HF-type tape. The wire harnesses thus obtained are then subjected to hot oxidizing tests. As a result, the wire harness made of a mixed cable bundle shows a much worse hot oxidizing property than the wire harness made of a HF-type plain cable bundle. The main cause of this difference may also reside in the fact that, in the mixed cable bundles, there occurs a migration of the plasticizers and adhesive adjuvants between the PVC-type electrical cables and the HF-type electrical cables. The anti-oxidizing agent and copper damage inhibitor must therefore be prevented from diffusing, and the migration of the plasticizers and adhesive adjuvants must be stopped.
[0037] As is well known, the adhesives painted on a base material (e.g. tape-shaped) of PVC- or HF-type protecting material are traditionally supplemented with plasticizers and adhesive adjuvants which tend to migrate. However, repeated experiments suggested that a high molecular polymer, which migrates less and has a sufficient adhesive power, should be used as base polymer of the adhesive.
[0038] As to the tape base of PVC- and HF-type protecting materials, if it is supplemented with an adsorbent agent, the latter may adsorb the plasticizers and prevent the latter from migrating.
[0039] As to the anti-oxidizing agent and copper damage inhibitor, if their concentration is suitably balanced between the HF-type electrical cable and the PVC-type protecting material, or between the HF-type electrical cable and the PVC-type electrical cable, their diffusion from the HF-type electrical cable to the PVC-type protecting material and the PVC-type electrical cable may be efficiently prevented, even though the plasticizers and adhesive adjuvants may not be completely immobilized.
[0040] Accordingly, another object of the invention is to provide a wire harness comprising a plain cable bundle made of HF-type electrical cables alone, or a mixed cable bundle in which part of the HF-type electrical cables is replaced by PVC-type electrical cables. In particular, when the harness-protecting material comprises a tape base painted with an adhesive, the plasticizers and adhesive adjuvants must be prevented from migrating, whilst the anti-oxidizing agent and copper damage inhibitor are prevented from moving from the HF-type electrical cables to the PVC-type protecting material and the PVC-type electrical cables. In this manner, the harness-protecting material procures a good anti-hot oxidation property, and the wire harness comprising this material obtains a stable and durable cable quality.
SUMMARY OF THE INVENTION
[0041] To the above end, there is provided a harness-protecting material comprising a base material comprising two faces, at least one face of which is coated with an adhesive;
[0042] the base material comprising a base organic material portion which includes a base polymer portion formed of a halogen-free resin or a substantially halogen-free resin; and
[0043] the adhesive comprising a base organic material portion which includes a base polymer portion, and an adhesive adjuvant which contains at least one compound selected from the group consisting of a hydrogenated terpene-type resin, a hydrogenated aromatic resin, a hydrogenated aliphatic-type resin, a cumarone-indene type resin, a phenol-type resin and a styrene-type resin.
[0044] Preferably, the adhesive contains an acrylic acid-type resin as the base polymer portion.
[0045] Preferably yet, the adhesive adjuvant is added in a proportion of about 10 to about 200 parts by weight, relative to 100 parts by weight of the base polymer portion of the adhesive.
[0046] Typically, at least one of the base material and the adhesive contain(s) at least one agent selected from the group consisting of an anti-oxidizing agent, a copper damage inhibitor and an adsorbent.
[0047] The adsorbent may comprise at least one of carbon black and silica.
[0048] Typically, the adsorbent is added in a proportion of about 1 to about 150 parts by weight, relative to 100 parts by weight of the base polymer portion of the adhesive, and/or in a proportion of about 1 to about 150 parts by weight, relative to 100 parts by weight of the base polymer portion of the base material.
[0049] The harness-protecting material of the invention may be adapted to cover a cable bundle that comprises at least one electrical cable covered with a halogen-free or substantially halogen-free cable coating which contains a determined amount of anti-oxidizing agent relative to parts by weight of base organic material portion of the halogen-free or substantially halogen-free cable coating. In such a case, the base material and/or the adhesive of the harness-protecting material preferably contain(s) about 10 to about 500% by weight of anti-oxidizing agent, with regard to the determined amount in the halogen-free or substantially halogen-free cable coating.
[0050] Suitably, the base material and/or the adhesive contain(s) parts by weight of anti-oxidizing agent equivalent to the determined amount in the halogen-free or substantially halogen-free cable coating.
[0051] Suitably yet, the anti-oxidizing agent used in the base material and/or adhesive is of the same type as the anti-oxidizing agent used in the halogen-free or substantially halogen-free cable coating.
[0052] Preferably, the copper damage inhibitor is added in a proportion of about 0.001 to about 5 parts by weight, relative to 100 parts by weight of the base organic material portion of the base material, and/or in a proportion of about 0.001 to about 5 parts by weight, relative to 100 parts by weight of the base organic material portion of the adhesive.
[0053] The harness-protecting material of the invention may be adapted to cover a cable bundle that comprises at least one electrical cable covered with a halogen-free or substantially halogen-free cable coating which contains a determined amount of copper damage inhibitor relative to parts by weight of base organic material portion of the halogen-free or substantially halogen-free cable coating. In such a case, the base material and/or the adhesive of the harness-protecting material preferably contain(s) parts by weight of copper damage inhibitor equivalent to the determined amount in the halogen-free or substantially halogen-free cable coating.
[0054] Typically, the base material is in the form of a tape.
[0055] The substantially halogen-free resin defined above may contain 5% by weight, more preferably 2% by weight, of halogen at the most, relative to the total amount of resin including additives.
[0056] The invention also relates to a wire harness comprising a harness-protecting material, the material including a base material comprising two faces, at least one face of which is coated with an adhesive;
[0057] the base material comprising a base organic material portion which includes a base polymer portion formed of a halogen-free resin or a substantially halogen-free resin; and
[0058] the adhesive comprising a base organic material portion which includes a base polymer portion, and an adhesive adjuvant which contains at least one compound selected from the group consisting of a hydrogenated terpene-type resin, a hydrogenated aromatic resin, a hydrogenated aliphatic-type resin, a cumarone-indene type resin, a phenol-type resin and a styrene-type resin.
[0059] Preferably, the adhesive contains an acrylic acid-type resin as the base polymer portion.
[0060] Preferably yet, the adhesive adjuvant is added in a proportion of about 10 to about 200 parts by weight, relative to 100 parts by weight of the base polymer portion of the adhesive.
[0061] Typically, at least one of the base material and the adhesive contain(s) at least one agent selected from the group consisting of an anti-oxidizing agent, a copper damage inhibitor and an adsorbent. preferably, the adsorbent comprises at least one of carbon black and silica.
[0062] Suitably, the adsorbent is added in a proportion of about 1 to about 150 parts by weight, relative to 100 parts by weight of the base polymer portion of the adhesive, and/or in a proportion of about 1 to about 150 parts by weight, relative to 100 parts by weight of the base polymer portion of the base material.
[0063] In the wire harness of the invention, the harness-protecting material may cover a cable bundle that comprises at least one electrical cable covered with a halogen-free or substantially halogen-free cable coating which contains a determined amount of anti-oxidizing agent relative to parts by weight of base organic material portion of the halogen-free or substantially halogen-free cable coating. In such a case, the base material and/or the adhesive of the harness-protecting material preferably contain(s) about 10 to about 500% by weight of anti-oxidizing agent, with regard to the determined amount in the halogen-free or substantially halogen-free cable coating.
[0064] Typically, the base material and/or the adhesive contain(s) parts by weight of anti-oxidizing agent equivalent to the determined amount in the halogen-free or substantially halogen-free cable coating.
[0065] Preferably, the anti-oxidizing agent used in the base material and/or adhesive is of the same type as the anti-oxidizing agent used in the halogen-free or substantially halogen-free cable coating.
[0066] In the above invention, the copper damage inhibitor is preferably added in a proportion of about 0.001 to about 5 parts by weight, relative to 100 parts by weight of the base organic material portion of the base material, and/or in a proportion of about 0.001 to about 5 parts by weight, relative to 100 parts by weight of the base organic material portion of the adhesive.
[0067] In the wire harness according to the invention, the harness-protecting material may cover a cable bundle that comprises at least one electrical cable covered with a halogen-free or substantially halogen-free cable coating which contains a determined amount of copper damage inhibitor relative to parts by weight of base organic material portion of the halogen-free or substantially halogen-free cable coating. In such a case, the base material and/or the adhesive of the harness-protecting material preferably contain(s) parts by weight of copper damage inhibitor equivalent to the determined amount in the halogen-free or substantially halogen-free cable coating.
[0068] In the above harness-protecting material, an adhesive is painted on at least one surface of the tape base made of a HF-type resin or vinyl chloride resin, and this adhesive contains an adhesive adjuvant composed of one or several specific resin(s) having low reactivity and less prone to bond with other atoms and molecules. Such adhesive adjuvants include, for instance, a hydrogenated terpene-type resin, a hydrogenated aromatic resin, a hydrogenated aliphatic resin, cumarone-indene type resin, a phenol-type resin and a styrene-type resin.
[0069] Accordingly, even if the adhesive adjuvants move into the cable coatings, they do not act on the wire conductors made of copper. In this manner, the catalytic copper ions can be prevented from being formed in the cable coatings, and copper damage due to the migration of adhesive adjuvants is avoided. As a consequence, the deterioration of the electrical cables contained in wire bundles is considerably slowed down.
[0070] Further, in the above harness-protecting material, the adhesive adjuvant composed of one or several specific resin(s) may be added in a proportion of about 10 to about 200 parts by weight, relative to 100 parts by weight of base polymer portion of the adhesive. This proportion secures a sufficient adhesive power, while maintaining the ease with which the tape can be wrapped.
[0071] Further, in the above harness-protecting material, when an anti-oxidizing agent is added beforehand to the adhesive and/or the base material of the tape, its concentration gradient between the harness-protecting material and the cable coating can be minimized. Accordingly, the decrease in the anti-oxidizing agent contained in cable coatings due to the migration of adhesive-side deterioration accelerators and base material-side deterioration accelerators, can be suppressed or limited.
[0072] As explained above, in normal cases, copper ions are formed in the cable coatings due to the migration of adhesive-side deterioration accelerators and base material-side deterioration accelerators other than the adhesive adjuvants, and the copper damage inhibitors added beforehand to the cable coatings are consumed and cause copper damage. Even in such case, when a copper damage inhibitor is added to the adhesive and/or the base material of the tape beforehand, a copper damage inhibitor is newly supplied to from the harness-protecting material to the cable coatings. The copper damage can thus be securely avoided.
[0073] Accordingly, the use of one or several resin(s) specifically chosen among the above-cited resins as adhesive adjuvants, on the one hand, and the inclusion of an anti-oxidizing agent and/or copper damage inhibitor in the adhesive and/or base material of the tape, on the other, produce a synergetic effect, and can efficiently prevent the deterioration of the electrical cables contained in cable bundles.
[0074] Further, in the above harness-protecting material, the proportion of anti-oxidizing agent over 100 parts by weight of base organic material portion of the adhesive (e.g. SBR, natural rubber and an adhesive adjuvant) and/or those of the base material of the tape (e.g. PVC and DOP) may range from about 10 to about 500% by weight (i.e. about 0.1 to 5 times), relative to parts by weight of anti-oxidizing agent over base organic material portion (e.g. polypropylene) contained in the coatings of the HF-type resin-coated electrical cables which are included in a cable bundle wrapped with a harness-protecting material. In this manner, the concentration of anti-oxidizing agents is well balanced between the harness-protecting material and the cable coatings. Accordingly, the decrease in the anti-oxidizing agent contained in cable coatings, due to the migration of adhesive-side deterioration accelerators and base material-side deterioration accelerators, can be suppressed or limited efficiently.
[0075] Further, the copper damage inhibitor may be added to the adhesive in a proportion of about 0.001 to about 5 parts by weight, relative to 100 parts by weight of base organic material portion (e.g. SBR, natural rubber and an adhesive adjuvant) of the adhesive. Likewise, the copper damage inhibitor may be added to the tape base material in a proportion of about 0.001 to about 5 parts by weight, relative to 100 parts by weight of base organic material portion (e.g. PVC and DOP) of the tape base material. The addition of the copper damage inhibitor to the cable coatings thus produces a great beneficial effect, and does not deteriorate the quality of the harness-protecting material.
[0076] Accordingly, the use of one or several resin(s) specifically chosen among the above-cited resins as adhesive adjuvants, on the one hand, and the inclusion of an anti-oxidizing agent and/or copper damage inhibitor in the adhesive and/or base material of the tape, on the other, produces a synergetic effect, and can efficiently prevent the deterioration of the electrical cables contained in a cable bundle.
[0077] According to the above harness-protecting material, the anti-oxidizing agents used in the adhesive and/or tape base material and in the cable coatings may be of the same type. The concentration of the anti-oxidizing agent can thus be easily balanced between the harness-protecting material and the cable coatings. The decrease in the anti-oxidizing agent contained in cable coatings due to the migration of adhesive-side deterioration accelerators and tape base material-side deterioration accelerators, can be suppressed or limited more efficiently.
[0078] According to the above wire harness, the electrical cables contained in a cable bundle do not deteriorate in a substantial way. The quality of the wire harness can thus be maintained for long.
[0079] Further, even if a cable bundle contains electrical cables coated with a HF-type resin and those coated with vinyl chloride resin as a mixture, the HF-type resin coated cables do not deteriorate in a substantial manner, and the wire harness can maintain its quality for an appreciably long time.
[0080] As a second aspect of the invention, in the above harness-protecting material, the adhesive and/or the tape base material contain(s) an adsorbent, which adsorbs the adhesive-side deterioration accelerators such as an adhesive adjuvant and the tape base material-side deterioration accelerators such as a plasticizer. In this manner, both types of deterioration accelerators are blocked in the harness-protecting material and prevented from moving into the cable coatings. Accordingly, the copper damage due to the migration of adhesive-side deterioration accelerators and tape base material-side deterioration accelerators, as well as the decrease in the anti-oxidizing agent contained in cable coatings, can be suppressed or limited, and the deterioration of the electrical cables contained in a cable bundle can be slowed down considerably.
[0081] Even if the adhesive adjuvant is not adsorbed by the adsorbent in totality and part of adjuvant moves into the cable coatings, the adjuvant does not act on the cable's conductor element made of copper. Thus, the formation of copper ions in the cable coatings is prevented or restricted. Accordingly, the copper damage owing to the adhesive adjuvant is securely avoided, and the deterioration of the electrical cables in a cable bundle owing to the immigration of the adhesive adjuvant is considerably slowed down.
[0082] In the above harness-protecting material, the adsorbent may be added to the adhesive in a proportion of about 1 to about 150 parts by weight, relative to 100 parts by weight of base polymer portion (e.g. SBR and natural rubber) of the adhesive. Likewise, the adsorbent may be added to the tape base material in a proportion of about 1 to about 150 parts by weight, relative to 100 parts by weight of base polymer portion (e.g. PVC) of the tape base. The addition of adsorbent to the wire coatings thus produces a great beneficial effect, whilst it does not impede the wrapping operation. Further, the adhesive adjuvant is added in a proportion of about 10 to about 200 parts by weight, relative to 100 parts by weight of adhesive's base polymer portion (e.g. SBR and natural rubber). Accordingly, a sufficient adhesive capacity is maintained, and the wrapping operation is not damaged.
[0083] Further, in the above harness-protecting material, the adhesive-side deterioration accelerators and the tape base-side deterioration accelerators may not be adsorbed by the adsorbent in totality and part of accelerators may move into the wire coatings. Even in such case, when the anti-oxidizing agent is added to the adhesive and/or tape base beforehand, the concentration gradient of anti-oxidizing agent between the harness-protecting material and the cable coatings can be minimized. Accordingly, the decrease in the anti-oxidizing agent contained in cable coatings, owing to the migration of adhesive-side deterioration accelerators and base material-side deterioration accelerators, can be suppressed or limited.
[0084] On the other hand, when the adhesive and/or the tape base contain(s) a copper damage inhibitor, copper ions may be formed in the cable coatings, owing to the migration of the adhesive-side deterioration accelerators and tape base-side deterioration accelerators which are not adsorbed by the adsorbent. Then, the copper damage inhibitor contained in the cable coatings beforehand may be consumed, and cause copper damage. Even in such case, the copper damage inhibitor is freshly supplied from the harness-protecting material to the cable coatings, so that the copper damage can be securely prevented.
[0085] There are thus produced three effects: the effect of adding the adsorbent to the adhesive and/or tape base, the effect of using one or several resins chosen from the specific resins as adhesive adjuvant, and the effect of adding the anti-oxidizing agent and/or copper damage inhibitor to the adhesive and/or tape base. Thanks to these effects, the electrical cables contained in a cable bundle can be efficiently prevented from the deterioration.
[0086] As mentioned supra, the proportion of the anti-oxidizing agent added to the base organic material portion of adhesive and/or tape base material in the harness-protecting material may range from about 10 to about 500% by weight, relative to that of the anti-oxidizing agent added to the base organic material portion of the coatings of HF-type resin-coated electrical cables which are included in a wire bundle wrapped with harness-protecting materials. In this manner, the concentration of anti-oxidizing agents is well balanced between the harness-protecting material and the cable coatings. Accordingly, the decrease in the anti-oxidizing agent contained in cable coatings, due to the migration of adhesive-side deterioration accelerators and tape base-side deterioration accelerators, can be suppressed or limited efficiently.
[0087] Further, the copper damage inhibitor may be added to the adhesive in a proportion of about 0.001 to about 5 parts by weight, relative to 100 parts by weight of base organic material portion of the adhesive. Likewise, the copper damage inhibitor may be added to the tape base in a proportion of about 0.001 to about 5 parts by weight, relative to 100 parts by weight of base organic material portion of the tape base material. The addition of the copper damage inhibitor to the cable coatings thus produces a great beneficial effect, whilst it does not deteriorate the quality of the harness-protecting material.
[0088] Thus, the inclusion of adsorbent in the adhesive and/or tape base, the use of one or several resin(s) specifically chosen among the above-cited resins as adhesive adjuvant, and the inclusion of an anti-oxidizing agent and/or copper damage inhibitor in the adhesive and/or base material of the tape produce a synergetic effect, and can efficiently prevent the deterioration of the electrical wires contained in wire bundles.
[0089] According to the above harness-protecting material, the anti-oxidizing agents used in the adhesive and/or tape base material and in the cable coatings may belong to the same type. The concentration of the anti-oxidizing agent can thus be easily balanced between the harness-protecting material and the cable coatings. The decrease in the anti-oxidizing agent contained in cable coatings, due to the migration of adhesive-side deterioration accelerators and tape base material-side deterioration accelerators, can be thus suppressed or limited more efficiently.
[0090] According to the above wire harness, the electrical cables contained in a cable bundle do not deteriorate in a substantial way. The quality of the wire harness can thus be maintained for long time.
[0091] Further, even if a cable bundle contains electrical cables coated with a HF-type resin and those coated with vinyl chloride resin as a mixture, the HF-type resin coated cables do not deteriorate in a substantial manner, and the wire harness can maintain its quality for an appreciably long time.
[0092] In the above harness-protecting material, the adhesive painted on the surface of the tape base may contain an acrylic acid-type resin as base polymer portion, so that the harness-protecting material can maintain a good anti-hot oxidation property. As a result, the insulated HF-type electrical cables are prevented from the decrease in anti-hot oxidation property.
[0093] Further, the tape base and/or adhesive preferably contain(s) an adsorbent.
[0094] Examples of adsorbent include silica, carbon black, calcium carbonate, magnesium carbonate and clay. For instance, when carbon black is used, the tape base and/or adhesive become more durable at least. When silica is used, at least the heat and acid resistance of the tape base and/or adhesive is improved. Accordingly, the addition of an adsorbent to the tape base and/or adhesive reinforces the protection of the insulated HF-type electrical cables, and prevents the latter from the decrease in anti-hot oxidation property.
[0095] When the tape base used is vinyl chloride-type resin material, the adsorbent adsorbs the plasticizer and acrylic acid-type resin, which are thus prevented from migrating from the adhesive-painted tape base into the insulated HF electrical cables. The insulated HF-type electrical cables are thus prevented from the deteriorating in anti-hot oxidation property. As to base polymers of the vinyl chloride-type resin material, any compound suitable as base polymer portion for the cable coatings in the insulated PVC-type electrical cables may be used. To this is added, where appropriate, a plasticizer, a stabilizer, etc.
[0096] When the tape base used is a HF-type resin material, the addition of an adsorbent improves the anti-hot oxidation property of the tape base. The insulated HF-type electrical cables are thus prevented from the degradation in anti-hot oxidation property. As to base polymers of the HF-type resin material, any compound suitable as base polymer portion for the cable coatings in the insulated HF electrical cables may be used. To this may be added a bromine-based flame-retardant containing low halogen. There can also be used a HF-type flame-retardant e.g. a metal hydrate such as magnesium hydroxide and aluminium hydroxide.
[0097] When the amount of adsorbent is less than about 1 part by weight (based on the definition supra), there is no effect. Conversely, when it is more than 150 parts by weight, workability deteriorates. A preferred amount range is between about 5 and about 100 parts by weight. When the amount is less than 5 parts by weight, the effect of the adsorbent is rather weak. Conversely, when it is more than 100 parts by weight, workability somewhat deteriorates.
[0098] As anti-oxidizing agent and copper damage inhibitor, any compound suitable for the insulated HF-type electrical cables may be used. When the anti-oxidizing agent and/or copper damage inhibitor are added to the tape base and/or adhesive, the anti-oxidizing agent and/or copper damage inhibitor contained in the cable coatings of the insulated HF-type electrical cables are prevented from diffusing into the harness-protecting material (adhesive, tape base, tube, sheet). The insulated HF-type electrical cables are thus prevented from the deterioration of anti-hot oxidation property.
[0099] When the tape base used is a HF-type resin material and the anti-oxidizing agent and/or copper damage inhibitor is/are added to the HF-type protecting material (tape base and/or adhesive), the insulated HF-type electrical cables are affected less by water in the air and the adhesive, as the HF-type protecting material acts as a barrier. The insulated HF-type electrical cables are thus prevented from the lowering of their anti-hot oxidation property. When the conductor element used is a copper wire, the copper damage inhibitor contained in the cable coatings of the insulated HF-type electrical cables is efficiently consumed, such that the copper ions generated by the reaction of water in the air with the copper wire, are stabilized. The insulated HF-type electrical cables are thus prevented from the lowering of their anti-hot oxidation property.
[0100] There is little concentration gradient of the anti-oxidizing agent and/or copper damage inhibitor between the insulated HF-type electrical cables and the harness-protecting material (tape base and adhesive). This lack of gradient prevents both agents from being diffused.
[0101] In the wire harness of the invention, the harness-protecting material wrapped around the electrical bundle contains an adhesive, and the latter may contain an acrylic acid-type resin. Further, the tape base and/or adhesive contain, where appropriate, an adsorbent, an anti-oxidizing agent and/or a copper damage inhibitor, so that the anti-hot oxidation property of the insulated HF-type electrical cable can be maintained easily.
[0102] When the tape base used is a vinyl chloride-type resin material, the adsorbent adsorbs the plasticizer, so that the plasticizer is prevented from migrating from the adhesive-painted tape into the insulated HF-type electrical cable. The latter is thus prevented from the deterioration of its anti-hot oxidation property. When the tape base used is a HF-type resin material, the anti-hot oxidation property of the adhesive-painted tape is improved, not to mention being prevented from the deterioration.
[0103] As already mentioned, the copper damage inhibitor and/or anti-oxidizing agent are prevented from diffusing from the insulated HF-type electrical cables into the insulated vinyl chloride electrical cable and harness-protecting material. The insulated HF-type electrical cables are thus prevented from the deterioration of their anti-hot oxidation property.
[0104] Preferably, the copper damage inhibitor and/or anti-oxidizing agent contained in each electrical cable and harness-protecting material belong to the same type. Although there exist many kinds of copper damage inhibitor and anti-oxidizing agent, by using the same type, their concentration equilibrium can be maintained more appropriately and efficiently.
BRIEF DESCRIPTION OF THE DRAWINGS
[0105] The above, and the other objects, features and advantages of the present invention will be made apparent from the following description of the preferred embodiments, given as non-limiting examples, with reference to the accompanying drawings, in which:
[0106] [0106]FIG. 1( a ) is a cross-sectional view of a tape, one face of which is painted with an adhesive;
[0107] [0107]FIG. 1( b ) is a cross-sectional view of a tape, both faces of which are painted with an adhesive;
[0108] [0108]FIG. 2( a ) is a perspective view of a cable bundle wrapped with a tube, then with tapes one face of which is painted with an adhesive;
[0109] [0109]FIG. 2( b ) is a perspective view of a cable bundle wrapped with a sheet, then with tapes one face of which is painted with an adhesive;
[0110] [0110]FIG. 2( c ) is a perspective view of a cable bundle wrapped with tapes one face of which is painted with an adhesive; and
[0111] [0111]FIG. 3 is a perspective view of a cable bundle wrapped with tapes both faces of which are painted with an adhesive.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0112] In the present invention, FIG. 1 shows the cross-section of a tape painted with an adhesive. FIG. 1 a shows a tape 10 in which one face of a tape base 12 is painted with an adhesive, forming an adhesive layer 14 , whilst FIG. 1 b shows a tape 16 in which both faces of a tape base 12 is painted with an adhesive, forming adhesive layers 18 a and 18 b. The length and width of the tapes 10 and 16 is appropriately chosen depending on the applied location.
[0113] [0113]FIG. 2 shows an example of wire harness prepared by using a tape 10 of which one face is painted with an adhesive. FIG. 2 a shows an external view of a wire harness 24 , in which the cable bundle 22 is passed through a tube 20 , and one-side painted tapes 10 are wound around both ends of the tube 20 , so that the space between the tube 20 and the cable bundle 22 is closed. FIG. 2 b shows an external view of a wire harness 28 , in which the electrical cables 22 are wrapped with a sheet 26 , and one-side painted tapes 10 are wound around both ends of the sheet 26 , so that the space between the tube 20 and the cable bundle 22 is closed. FIG. 2c shows an external view of a wire harness 30 , in which one-side painted tapes 10 are merely wound around the cable bundle 22 .
[0114] [0114]FIG. 3 show an example of wire harness 34 prepared by using a tape 16 , both faces of which are painted with adhesives. In this example, the tape 16 is adhered to the end portions of the sheet 32 , then the sheet 32 is wrapped around the cable bundle 22 .
[0115] In the foregoing figures, the tape base 12 of the adhesive-painted tapes 10 and 16 contains a base polymer portion formed of a PVC resin, or of a HF-type resin which contains no halogen or contains halogen whose content is lower than that in the PVC-type resin. The tape base 12 contains, where necessary, an adsorbent, an anti-oxidizing agent and/or a copper damage inhibitor. Further, the cable bundle 22 may be a plain HF-type cable bundle, or a mixed cable bundle in which PVC electrical cables and HF-type electrical cables are mixed. An electrical conductor element 38 of each electrical cable 36 is composed of 7 soft copper wires.
[0116] In the figures, 30 electrical cables are formed into a cable bundle, and the latter is covered with a harness-protecting material (tape 10 and 16 , tube 20 , sheet 26 ).
[0117] The term “surface” in the present invention means part or the whole surface of one or both face(s) of the tape base.
[0118] For the purpose of the invention, additions of adhesive adjuvant and adsorbent are defined relative to “base polymer portion” of the tape base and/or adhesive, whilst additions of anti-oxidizing agent and copper damage inhibitor are defined relative to “base organic material portion” of the cable coating, tape base and/or adhesive, the both portions excluding the organic compounds used for anti-oxidizing agents and/or copper damage inhibitors.
[0119] The harness-protecting material of the invention is wrapped around a bundle of electrical cables (cable bundle), and comprises a base material in the form of a tape made of a HF-type resin or a vinyl chloride resin. At least one face of the tape base is painted with an adhesive, which contains a specific resin as adhesive adjuvant.
[0120] As to the cable coatings in the insulated HF-type electrical cables, examples of base polymer portion used as cable coatings include olefins e.g. propylene polymer (homopolymer and propylene random or block copolymer), polyethylene (high-density polyethylene, straight-chain low-density polyethylene, low-density polyethylene, ultra low-density polyethylene, etc.), polybutene polymer, ethylene copolymer (ethylene—vinyl acetate copolymer, ethylene—ethylacrylate copolymer, etc.), olefin-type elastomer (polypropylene—ethylene/propylene copolymer), or one of the above copolymers in which the double bond is saturated by hydrogenation. The above polymers may be used alone or in a mixture of several polymers. To these are added halogen-free flame-retardants, e.g. metal hydrates such as magnesium hydroxide and aluminium hydroxide. To these may be further added a copper damage inhibitor, an anti-oxidizing agent, and, where suitable, a formability adjuvant and a cross-linking agent for improving heat resistance. In the present invention, the anti-oxidizing agent and copper damage inhibitor are preferably added. Examples of low-halogen flame-retardants include bromide-type compounds. Flame-retardants may also include polymers containing halogen whose level is less than that of PVC resins (e.g. a retardant containing halogen atom, e.g. bromine, such as tetra-bromo bis-phenol A and its derivative).
[0121] Examples of anti-oxidizing agent contained in HF electrical cables include; phenol-type compounds e.g. tetrakis-[methylene-3-(3′,5′-di-tertiary-butyl-4′-hydroxyphenyl) propionate] methane and octa-decyl-3-(3,5-di-tertiary-butyl-4-hydroxyphenyl) propionate; and amine-type compounds e.g. 4,4′-dioctyldiphenylamine, N-phenyl-N′-1,3-dimethylbutyl-p-phenylenediamine. The anti-oxidizing agents may be used alone, or as a mixture of several agents.
[0122] Examples of copper damage inhibitor contained in HF electrical cables include 1,2,3-benzotriazole, tolyltriazole, and its derivatives, tolyltriazole amine salts, tolyltriazole potassium salts, 3-(N-salicyloyl)amino-1,2,4-triazole, a triazine-type derivative, a hydrazide-type compound e.g. decamethylene dicarboxylic acid disalicyloylhydrazide, oxalic acid derivatives and salicylic acid derivatives. These copper damage inhibitors may be used alone, or as a mixture of several agents.
[0123] As to the cable coatings in the insulated PVC-type electrical cables, examples of base polymer portion include, for example, polyvinyl chloride, ethylene—vinyl chloride copolymer, and propylene—vinyl chloride copolymer. The base polymers are supplemented with a plasticizer, which is easily mixable with the PVC resin, water-resistant and dielectric, in order to render the PVC resin flexible, improve its formability and reduce material costs. May further be added to this an anti-oxidizing agent which is suitable for the HF electrical cables.
[0124] The electrical conductor elements for insulated HF-type or PVC-type electrical cables include, for instance, annealed soft copper wires, tin-plated soft copper wires and tungsten wires, but are not limited to them.
[0125] As to the adhesive of the harness-protecting material, examples of its base polymer portion includes; a rubber-type resin containing natural and synthetic rubber; an acrylic acid-type resin; a silicone-type resin; a polyether-type resin; and a polyurethane-type resin. The base polymer may contains, besides adhesive adjuvants, a plasticizer, a softener, a filler and other additives, insofar as they serve for the object of the invention.
[0126] Examples of acrylic acid-type resin as adhesive include a homopolymer containing acrylic acid or its ester (e.g. ethyl acrylate, butyl acrylate and 2-ethythexyl acrylate) as sole or main monomers, or a copolymer of at least one of these monomers with another monomers e.g. vinyl acetate, methyl methacrylate and the like. The acrylic acid-type resins may be used alone, or as a mixture of several resins. Examples of acrylic acid ester suitable as acrylic acid-type resins include methyl acrylate, ethyl acrylate, propyl acrylate, butyl acrylate, 2-ethylhexyl acrylate, 2-hydroxyethyl acrylate, 2-hydroxypropyl acrylate, tetrafurfuryl acrylate and isononyl acrylate. The acrylic acid-type resins used have an adhesive nature. They may be an emulsion type, a solvent type, a hot melt type, a liquid-solidified type, a water-soluble type, a calendar-shaped type and a cross-linked type.
[0127] As a first aspect of the invention, the adhesive comprises an adhesive adjuvant. The adhesive adjuvants may comprise a hydrogenated terpene-type resin, a hydrogenated aromatic resin, a hydrogenated aliphatic resin, a cumarone-indene-type resin, a phenol-type resin, a styrene-type resin or a mixture of several of them.
[0128] The “hydrogenated terpene-type resin”, “hydrogenated aromatic resin” and “hydrogenated aliphatic resin” respectively mean a terpene-type resin to which hydrogen is added; a resin where a product obtained by polymerising C 5 fraction is hydrogenated; and a resin where a product obtained by polymerising C 9 fraction is hydrogenated.
[0129] Examples of hydrogenated terpene-type resin include a resin comprising poly (β-pinene), poly di-pentene, poly (α-pinene), α-pinene phenol, di-pentene phenol, terpene phenol and the like as skeletal structure, the latter being then hydrogenated.
[0130] Examples of hydrogenated aromatic resin include a resin comprising indene, styrene, methyl indene, α-methyl styrene and the like as skeletal structure, the latter being then hydrogenated.
[0131] Examples of hydrogenated aliphatic resin include a resin comprising isoprene, cyclopentadiene, 1,3-pentadiene, 1-pentene, 2-pentene, di-cycopentadiene and the like as skeletal structure, the latter being then hydrogenated.
[0132] The “cumarone-indene-type resin” means a resin obtained by polymerising a coal tar fraction containing cumarone resin and indene resin. The “phenol-type resin” means a resin obtained by polymerising phenol and its derivatives as main constituent. The “styrene-type resin” means a resin obtained by polymerising styrene and its derivatives as main constituent.
[0133] Examples of cumarone-indene-type resin include a resin comprising cumarone, indene, styrene, di-cyclopentadiene, a-methylstyrene and the like as skeletal structure.
[0134] Examples of phenol-type resin include a resin comprising an alkylphenol such as p-t-butylphenol as skeletal structure.
[0135] Examples of styrene-type resin include a resin comprising styrene, α-methylstyrene, p-methylstyrene and the like as skeletal structure.
[0136] The above resins may be prepared as functions of the type of base polymer portion of the adhesive, the degree of adhesion to be conferred, the costs and the purpose. When the adhesive adjuvant contains several specific resins, they may belong to the same type or different types of products. Their choice is not particularly limited.
[0137] The adhesive adjuvant is preferably added to the adhesive in a proportion of about 10 to about 200 parts by weight, relative to 100 parts by weight of base polymer portion (as defined supra) of the adhesive.
[0138] When the above amount added is less than 10 parts by weight, the adhesion tends to be insufficient, and when the amount is more than 200 parts by weight, the wrapping operation tends to become difficult. More preferably, the adhesive adjuvant is added in a proportion of about 20 to about 100 parts by weight, from the view point of tucking, adhesive and retaining power.
[0139] The tape base, painted with the above adjuvant-added adhesive, may be composed of any of HF-type resins and vinyl chloride resins.
[0140] The “HF-type resin” means a resin free of halogen, or a resin containing halogen atom less than so-called “vinyl chloride resin compound”. The “vinyl chloride resin compound” means a forming material in which vinyl chloride resin is supplemented with a plasticizer, a stabilizer and a filler, and the whole mixture is kneaded and shaped into a suitable form. Such a resin containing halogen atom less than the vinyl chloride resin compounds is referred to as “substantially halogen-free resin” in the present invention.
[0141] In other words, the HF-type resin of the invention comprises not only a resin containing no halogen, but also a low-halogen containing resin whose halogen content is less than that of known vinyl chloride resin compounds. The low-halogen containing resin includes cases in which the resin may contain halogen atoms in its resin structure or as additives e.g. flame-retardant, but the resin's halogen content is in any case less than that of vinyl chloride resin compound.
[0142] A known vinyl chloride resin compound typically contains 35% by weight of halogen, relative to the total amount of compound including additives.
[0143] Examples of HF-type resin include a non-halogen non-combustible olefin-type resin, in which an olefin resin (e.g. polypropylene, polyethylene and propylene-ethylene copolymer) is supplemented with a flame-retardant (a non-halogen flame-retardant e.g. magnesium hydroxide and aluminium hydroxide or a halogen-containing flame-retardant e.g. tetra-bromo bis-phenol and its derivatives), an anti-oxidizing agent (e.g. phenol- or amine-type compound), and/or a copper damage inhibitor (e.g. a triazine-type derivative). However, the HF-type resin of the invention is not limited to the above examples.
[0144] The “vinyl chloride resin” means homopolymer of vinyl chloride or a copolymer which contains vinyl chloride as main constituent. They may also be mixed. Examples of such resin include polyvinyl chloride, ethylene-vinyl chloride copolymer and propylene-vinyl chloride copolymer.
[0145] Preferably, the adhesive and/or tape base contain(s) an anti-oxidizing agent and/or a copper damage inhibitor in a suitable amount.
[0146] The adhesive and/or the tape base may also contain an adsorbent such as carbon black and silica.
[0147] When various resins used for the adhesive and/or tape base are commonly used for other ends, each resin may not require any anti-oxidizing agent and/or copper damage inhibitor. According to the invention, even in such case, the harness-protecting material contains an anti-oxidizing agent and/or a copper damage inhibitor.
[0148] Polyvinyl chloride is commonly supplemented with a plasticizer, a heat stabilizer and the like, but often not with an anti-oxidizing agent. Accordingly, when the harness-protecting material of the invention utilizes polyvinyl chloride, it preferably contains an anti-oxidizing agent in a suitable amount.
[0149] The “anti-oxidizing agent” of the invention means an organic compound added for inhibiting or delaying the oxidation phenomenon, in which the physical and chemical properties of a high molecular material change with time under certain environmental factors and the material's performance deteriorates.
[0150] Examples of such agent include a phenol-type compound such as tetrakis-[methylene-3-(3′,5′-di-tertiary-butyl-4′-hydroxyphenyl) propionate] methane and octa-decyl-3-(3,5-di-tertiary-butyl-4-hydroxyphenyl) propionate; and amine-type compounds e.g. 4,4′-dioctyldiphenylamine, N-phenyl-N′-1,3-dimethylbutyl-p-phenylenediamine. The anti-oxidizing agents may be used alone, or as a mixture of several agents.
[0151] The ratio of the anti-oxidizing agent added to the adhesive and/or the base material of the tape preferably range from about 10 to about 500% by weight, relative to that of the anti-oxidizing agent (as defined supra) contained in the cable coatings of the HF-type resin-coated electrical cables which are included in a cable bundle wrapped with harness-protecting materials.
[0152] When the amount used is less than 10% by weight, a sufficient effect may not be obtained. When the amount is more than 500% by weight, handling operation becomes difficult and not practical. In order to efficiently prevent the anti-oxidizing agent from moving from the cable coatings into the harness-protecting material, the amount is preferably limited to between about 10 and about 150% by weight. The anti-oxidizing agent used in the adhesive and/or tape base and that in the cable coatings belong preferably to the same type.
[0153] The “ratio of anti-oxidizing agent” contained in the cable coatings in which the electrical cables are coated with a HF-type resin supplemented with an anti-oxidizing agent means the ratio by weight of the anti-oxidizing agent relative to the base organic material portion of the cable coatings (i.e. coating's organic component excluding the anti-oxidizing agent).
[0154] When the ratio of anti-oxidizing agent in the cable coatings is e.g. 3% by weight, the adhesive and/or tape base preferably contains about 0.3 (in case of 10% equivalent supra) to about 15% (in case of 500% equivalent supra) by weight of anti-oxidizing agent.
[0155] The copper damage inhibitor is usually included in the coatings covered around a conductor made mainly of copper. It captures catalytically active copper ions as chelate compounds and stabilizes the cable coatings. The copper damage inhibitor thus prevents the deterioration of the cable coating resin due to copper ions.
[0156] Examples of copper damage inhibitor contained in HF electrical cables include 1,2,3-benzotriazole, tolyltriazole, and its derivatives, tolyltriazole amine salts, tolyltriazole potassium salts, 3-(N-salicyloyl) amino-1,2,4-triazole, a triazine-type derivative, a hydrazide-type compound e.g. decamethylene dicarboxylic acid disalicyloylhydrazide, oxalic acid derivatives and salicylic acid derivatives.
[0157] A low melting point anti copper agent is usually preferred, since it is easily dissolved and moves into the cable coatings, when the harness-protecting material is heated. These copper damage inhibitors may be used alone, or as a mixture of several agents.
[0158] The copper damage inhibitor may be added to the adhesive in a proportion of about 0.001 to about 5 parts by weight, relative to 100 parts by weight of base organic material portion of the adhesive. Likewise, the copper damage inhibitor may be added to the tape base material in a proportion of about 0.001 to about 5 parts by weight, relative to 100 parts by weight of base organic material portion of the tape base.
[0159] When the quantity is less than 0.001 parts by weight, the effect of the invention is not sufficient. When the amount is more than 5 parts by weight, the additives precipitate on the surface of the resin and crystallize thereon (formation of bloom). These crystals tend to hurt the quality. In order to reinforce the effect of supplying the copper damage inhibitor to the cable coatings, the agent is preferably added in a proportion of about 0.01 to about 5 parts by weight.
[0160] The effect of the harness-protecting material is explained in more detail hereunder.
[0161] In the harness-protecting material of the invention, the adhesive is painted on at least one face of the tape base made of a HF-type resin or vinyl chloride resin, and the adhesive contains an adhesive adjuvant. The adhesive adjuvants include, as mentioned supra, a hydrogenated terpene-type resin, a hydrogenated aromatic resin, a hydrogenated aliphatic resin, cumarone-indene type resin, a phenol-type resin, a styrene-type resin and a mixture thereof. A low reactivity resin, less prone to bond to other atoms or molecules, is preferably used.
[0162] Accordingly, even if the adhesive adjuvant moves into the cable coatings, it does not react with the electrical conductors made of copper. The catalytically active copper ions are thus prevented from being formed in the cable coatings, and the copper damage caused by the movement of the adhesive adjuvant can be avoided. The deterioration of the electrical cables contained in cable bundles is then considerably slowed down.
[0163] Further, when the adhesive and/or tape base contain an anti-oxidizing agent beforehand, the concentration gradient of the agent between the harness-protecting material and the cable coating can be minimized. Consequently, the decrease in anti-oxidizing agent in the cable coating, caused by the migration of the adhesive-side and the tape base-side deterioration accelerators, can be limited or stopped.
[0164] In the above case, the anti-oxidizing agent in the adhesive and/or tape base and that in the cable coating are preferably of the same type. In this manner, the concentration equilibrium of the agent can be easily attained between the harness-protecting material and the cable coating. Consequently, the decrease in anti-oxidizing agent in the cable coating, caused by the migration of the adhesive-side and the tape base-side deterioration accelerators, can be limited or stopped more efficiently.
[0165] The catalytically active copper ions may be formed in the cable coatings, due to the migration of the adhesive-side and the tape base-side deterioration accelerators, other than the adhesive adjuvants. The previously-added copper damage inhibitor is then consumed and causes copper damage. In such a case, when the adhesive and/or tape base contain a copper damage inhibitor beforehand, the latter is supplied freshly from the harness-protecting material into the cable coating, and copper damage can be securely prevented.
[0166] As the adhesive adjuvant comprises one or several specific resin(s) indicated above and the adhesive and/or tape base contain(s) an anti-oxidizing agent and/or a copper damage inhibitor, such a combined application produces a synergic effect, and cable deterioration can be avoided in an efficient manner.
[0167] In the present harness-protecting material, the adhesive adjuvant composed of one or several specific resin(s) is preferably added in a proportion of about 10 to about 200 parts by weight, relative to 100 parts by weight of base polymer portion of the adhesive. Under such conditions, a required adhesive power is secured and the wrapping operation is not adversely affected.
[0168] As already mentioned, the anti-oxidizing agent contained in the adhesive and/or tape base is preferably added in a proportion of about 10 to about 500% by weight, relative to the anti-oxidizing agent contained in the coatings of the HF-type resin-coated electrical wires which are included in a cable bundle wrapped with harness-protecting materials.
[0169] In the above range, the concentration equilibrium of the agent is maintained between the harness-protecting material and the cable coating. As a result, the decrease in anti-oxidizing agent in the cable coating, due to the migration of the adhesive-side and tape base-side deterioration accelerators, can be efficiently limited or suppressed.
[0170] The copper damage inhibitor is preferably added to the adhesive in a proportion of about 0.001 to about 5 parts by weight, relative to 100 parts by weight of base organic material portion of the adhesive. Likewise, it is preferably added to the tape base in a proportion of about 0.001 to about 5 parts by weight, relative to 100 parts by weight of base organic material portion of the base material.
[0171] In the above range, the copper damage inhibitor is efficiently supplied to the cable coating, and the quality of the harness-protecting material is not damaged.
[0172] When the adhesive adjuvant is appropriately included in the adhesive, whilst the anti-oxidizing agent and/or copper damage inhibitors are suitably included in the adhesive and/or tape base, a synergic effect is produced by the specific resins used for the adhesive adjuvant and the anti-oxidizing agent and copper damage inhibitor added in the adhesive and/or tape base. The degradation of the electrical cables in cable bundles can thus be prevented more efficiently.
[0173] The wire harnesses composed of a cable bundle and a harness-protecting material wrapped therearound will be explained hereunder.
[0174] Examples of cable bundle of the invention include a plain cable bundle comprising only electrical cables coated with a HF-type resin containing an anti-oxidizing agent; a mixed cable bundle comprising, in a given proportion, i) electrical cables coated with a HF-type resin containing an anti-oxidizing agent and ii) electrical cables coated with a vinyl chloride resin; and a plain cable bundle comprising only electrical cables coated with a vinyl chloride resin. The invention is not, however, limited to the above combination. In order to enhance the effect of use of the harness-protecting material, the cable bundle preferably contains at least one electrical cable coated with a HF-type resin containing an anti-oxidizing agent.
[0175] When the cable bundle contains, in a given ratio, the electrical cables coated with a HF-type resin with anti-oxidizing agent and the electrical cables coated with a vinyl chloride resin, the latter cable coating (i.e. vinyl chloride coating) preferably contains beforehand an anti-oxidizing agent in a proportion of about 10 to about 500% by weight, with respect to % by weight of anti-oxidizing agent (as defined supra) contained in the former cable coating (i.e. HF-type resin coating with anti-oxidizing agent). In this manner, the deterioration, due to the migration of the agent between the electrical cables, of the electrical cables coated with the anti-oxidizing agent-added HF-type resin may be reduced to the minimum.
[0176] According to the wire harness of the invention, the electrical cables in a cable bundle is well protected from the deterioration. In particular, even if the electrical cables coated with a HF-type resin and those coated with a vinyl chloride resin are mixed in the same cable bundle, the electrical cables with the HF-type coating are prevented from significant deterioration. The wire harness can thus retain a long-lasting quality.
[0177] Regarding the second aspect of the invention, the adhesive and/or tape base further contain(s) an adsorbent, whilst the adhesive contain an adhesive adjuvant made of a specific resin.
[0178] The above adsorbent captures adhesive-side deterioration accelerators such as adhesive adjuvants and tape base-side deterioration accelerators such as plasticizers. These accelerators are thus fixed in the harness-protecting material, and prevented from moving into the cable coatings. This phenomenon in turn prevents the copper damage and decrease in anti-oxidizing agent contained in the cable coating, which are caused by the migration of the adhesive-side and base material-side deterioration accelerators. As a result, the deterioration of individual cables contained in the cable bundle can be considerably slowed down.
[0179] The adhesive adjuvants contained in the adhesive are composed of a low-reactivity specific resin, which does not bond easily with other atoms or molecules. Even if the whole quantity of adhesive adjuvants is not adsorbed by the adsorbent and part of them moves into the cable coatings, this part of the adjuvants does not react with electrical conductors made of copper, and the formation of copper ions in the cable coatings can be avoided or limited. The copper damage owing to the adhesive adjuvants can thus be securely prevented, and the degradation of the electrical cables in the cable bundle is considerably delayed.
[0180] The adsorbent is added to the adhesive in a proportion of about 1 to about 150 parts by weight, relative to 100 parts by weight of base polymer portion of the adhesive. Likewise, the adsorbent is added to the tape base in a proportion of about 1 to about 150 parts by weight, relative to 100 parts by weight of base polymer portion of the tape base. The adsorption then produces a sufficient effect, and the wrapping operation can be performed easily.
[0181] When the adhesive adjuvant is added in a proportion of about 10 to about 200 parts by weight, relative to 100 parts by weight of adhesive's base polymer portion, a sufficient adhesive capacity is maintained and the wrapping operation is not affected.
[0182] Further, an anti-oxidizing agent may be added to the adhesive and/or tape base. In such cases, the whole quantity of adhesive-side deterioration accelerators and tape base-side deterioration accelerators may not be adsorbed by the adsorbent and part of them may move into the cable coatings. Even in such cases, the concentration gradient of the anti-oxidizing agent between the harness-protecting material and the cable coating can be reduced to the minimum. The decrease of the anti-oxidizing agent in the cable coating, due to the migration of adhesive-side deterioration accelerators and tape base-side deterioration accelerators, can thus be minimized or suppressed.
[0183] In the above case, the anti-oxidizing agent in the adhesive and/or tape base and that in the cable coating are preferably of the same type. In this manner, the concentration equilibrium of the agent can be easily attained between the harness-protecting material and the cable coating. Consequently, the decrease in anti-oxidizing agent in the cable coating caused by the migration of the adhesive-side and the tape base-side deterioration accelerators can be limited or stopped more efficiently.
[0184] The catalytically active copper ions may be formed in the cable coatings, due to the migration of the adhesive-side and the tape base-side deterioration accelerators, not adsorbed by the adsorbent. The previously added copper damage inhibitor is then consumed and causes copper damage. In such a case, when the adhesive and/or tape base contain(s) a copper damage inhibitor beforehand, the latter is supplied freshly from the harness-protecting material into the cable coating, and the copper damage can be securely prevented.
[0185] As mentioned supra, besides the use of adhesive and adhesive adjuvants, an anti-oxidizing agent may be added to the adhesive and/or tape base. Then, the effects of adding an adsorbent to the adhesive and/or tape base, of using one or several specific resin(s) indicated above as adhesive adjuvant, and of adding an anti-oxidizing agent and/or a copper damage inhibitor to the adhesive and/or tape base are combined, and further enhance the synergistic effect. The cable deterioration in cable bundles can thus be avoided in an efficient manner.
[0186] As a third aspect of the invention, the adhesive contains a base polymer portion formed of an emulsion-type acrylic acid resin. The adhesive contains, where necessary, an adsorbent, an anti-oxidizing agent and/or a copper damage inhibitor.
[0187] Embodiment 1
[0188] Electrical Cables
[0189] The harness-protecting material comprised an adhesive tape which wraps a cable bundle comprising a plurality of electrical cables. Three types of electrical cables were prepared. In all cases, electrical conductors used were soft copper wires.
[0190] The first type relates to electrical cables coated with a resin containing no halogen (HF-type resin). Table 1 shows the composition of this type of coating, in which 80 parts by weight of magnesium hydroxide as flame-retardant, 3 parts by weight of anti-oxidizing agent (e.g. phenol-type compound) and 1 part by weight of copper damage inhibitor were added, relative to 100 parts by weight of polypropylene (polyolefin-type compound) as base polymer portion.
[0191] The ratio of anti-oxidizing agent contained in the cable coating of HF electrical cables relative to the base polymer portion was:
[0192] 3:100.
[0193] The % of anti-oxidizing agent in the composition was:
(3/184)×100=1.63 wt %.
[0194] The ratio of copper damage inhibitor contained in the cable coating of HF-type electrical cables relative to the base polymer portion was:
[0195] 1:100.
[0196] The % of anti-oxidizing agent in the composition was:
(1/184)×100=0.54 wt %.
[0197] The second type relates to electrical cables coated with a vinyl chloride resin (PVC-type resin). Table 2 shows the composition of this type of coating, in which 40 parts by weight of diisononyl phthalate (DINP) as plasticizer, 20 parts by weight of calcium carbonate as fillers and 5 parts by weight of stabilizer (zinc-calcium type compound) were added, relative to 100 parts by weight of polyvinyl chloride (polymerization degree: 1300) as base polymer portion.
[0198] The cable coatings for this PVC-type electrical cables did not contain the anti-oxidizing agent.
[0199] The third type relates to electrical cables coated with a vinyl chloride resin containing an anti-oxidizing agent (PVC-type resin with anti-oxidizing agent). Table 3 shows the composition of this type of coating, in which 40 parts by weight of diisononyl phthalate (DINP) as plasticizer, 20 parts by weight of calcium carbonate as fillers, 5 parts by weight of stabilizer (e.g. zinc-calcium type compound) and 4.5 parts by weight of anti-oxidizing agent were added, relative to 100 parts by weight of polyvinyl chloride (polymerization degree: 1300) as base polymer portion.
[0200] The % of anti-oxidizing agent in the composition was:
(4.5/169.5)×100=2.65 wt %.
[0201] The ratio of anti-oxidizing agent contained in the cable coating of PVC-type electrical cables relative to the organic polymer (PVC and DINP) was:
4.5:140=3.2:100.
[0202] These three types of electrical cables respectively comprised an electrical conductor element having a cross-section of 0.5 mm 2 (outer diameter of about 1.0 mm). The conductor element was formed by intertwining seven soft copper wires respectively having a diameter of 0.32 mm. A coating material according to Table 1, 2 or 3 was mixed by a twin axis kneader and extruded around the conductor element, yielding a coating of 0.3 mm thick. In this manner, the HF-type electrical cables were prepared by mixing at 250° C. and formed into pellets by a pelletizer. The pellets were then extruded at 250° C. into a coating of 0.3 mm thick. Likewise, the PVC-type electrical cables and the PVC-type, anti-oxidizing agent-containing electrical cables were mixed at 180° C. and extruded at 180° C.
[0203] Table 4 shows the cable coatings and harness-protecting materials (adhesive tapes) used in the present invention, as well as names of the manufactures of those products.
[0204] Adhesive Tape as a Harness-Protecting Material
[0205] The adhesive tape as harness-protecting material of the invention is explained hereunder. Six types of adhesive tape were prepared.
[0206] Table 5 shows the composition of a first type of adhesive tape. The first type comprised a PVC-type anti-oxidizing adhesive tape (Examples 1 to 5), in which the tape base was formed of a vinyl chloride resin containing an anti-oxidizing agent, one face of which was painted with an adhesive that contained an adhesive adjuvant made of a specific resin, and an anti-oxidizing agent.
[0207] The tape base comprised 60 parts by weight of di-octylphthalate (DOP) as plasticizer, 20 parts by weight of calcium carbonate as fillers, 5 parts by weight of stabilizer and respectively 0.5, 5, 7.5, 12.5 and 25 parts by weight of anti-oxidizing agent, relative to 100 parts by weight of polyvinyl chloride. When expressed by weight ratio relative to the base organic material portion (PVC+DOP), the anti-oxidizing agents were contained in a ratio of, respectively, 0.3, 3.1, 4.7, 7.8 and 15.6 in the tape base. These ratios correspond to about 0.10, 1, 1.5, 2.5 and 5 times, relative to 3 weight ratio of anti-oxidizing agent, relative to 100 parts by weight of base organic material portion, contained in the cable coating of HF-type electrical cables. The tape base had a thickness of 0.11 mm.
[0208] The adhesive of Examples 1 to 5 comprised 70 parts by weight of styrene butadiene rubber, 30 parts by weight of natural rubber and 20 parts by weight of zinc white. Examples 1 to 5 further comprised, as adhesive adjuvant made of a specific resin, 80 parts by weight of, respectively, hydrogenated terpene-type resin, hydrogenated aromatic resin, hydrogenated aliphatic resin, cumarone-indene-type resin and phenol-type resin, as well as an anti-oxidizing agent of, respectively, 0.6, 6, 9, 14 and 28 parts by weight. The weight ratios of the above anti-oxidizing agent corresponded to 0.3, 3.3, 5, 7.8 and 15.5, respectively, relative to 100 parts by weight of base organic material portion. These ratios correspond to about 0. 1, 1, 1.5, 2.5 and 5 times, relative to 3 weight ratio of anti-oxidizing agent, relative to 100 parts by weight of base organic material portion, contained in the cable coating of HF-type electrical cables. The adhesive had a thickness of 0.02 mm.
[0209] Table 5 also comprises a Comparative Example 1, in which the ratio of anti-oxidizing agent contained in the tape base and adhesive of Example 5 was 6 times the ratio of anti-oxidizing agent in the cable coating of HF-type electrical cables. Table 5 further comprises Prior Art 1, in which the tape base and adhesive contained no anti-oxidizing agent, but contained, as adhesive adjuvant, a rosin-type resin instead of the foregoing specific resin.
[0210] A second type of the adhesive tape comprised a HF-type anti-oxidizing adhesive tape (Examples 6 to 10), in which the tape base was formed of a HF-type resin containing an anti-oxidizing agent, one face of which was painted with an adhesive that contained an adhesive adjuvant made of a specific resin, and an anti-oxidizing agent. Table 6 shows the composition of the HF-type anti-oxidizing adhesive tapes of Examples 6 to 10.
[0211] The tape base comprised 3 parts by weight of bromine-type flame-retardant, 1.5 parts by weight of antimony trioxide and respectively 0.4, 3.5, 5.5, 8 and 16 parts by weight of anti-oxidizing agent, relative to 100 parts by weight of polyolefin. When expressed by weight ratio relative to 100 parts by weight of base organic material portion (polyolefin+bromine-type flame-retardant), the anti-oxidizing agents were contained in a ratio of, respectively, 0.4, 3.4, 5.3, 7.8 and 15.5 in the tape base. These ratios correspond to about 0.10, 1, 1.5, 2.5 and 5 times, relative to 3 weight ratio of anti-oxidizing agent, relative to 100 parts by weight of base organic material portion, contained in the cable coating of HF-type electrical cables. The tape base had a thickness of 0.11 mm.
[0212] The adhesive of Examples 6 to 10 comprised 70 parts by weight of styrene butadiene rubber, 30 parts by weight of natural rubber and 20 parts by weight of zinc white. Examples 6 to 10 further comprised, as adhesive adjuvant made of a specific resin, 80 parts by weight of, respectively, hydrogenated terpene-type resin, hydrogenated aromatic resin, hydrogenated aliphatic resin, cumarone-indene-type resin and phenol-type resin, as well as an anti-oxidizing agent of, respectively, 0.6, 6, 9, 14 and 28 parts by weight. The weight ratios of the above anti-oxidizing agent correspond to 0.3, 3.3, 5, 7.8 and 15.5, respectively, relative to 100 parts by weight of base organic material portion. These ratios correspond to about 0.10, 1, 1.5, 2.5 and 5 times, relative to 3 parts by weight of anti-oxidizing agent (with regard to 100 parts by weight of base organic material portion), contained in the cable coating of HF-type electrical cables. The adhesive had a thickness of 0.02 mm.
[0213] Table 6 also comprises a Comparative Example 2, in which the ratio of anti-oxidizing agent contained in the tape base and adhesive of Example 10 was 6 times the parts by weight of anti-oxidizing agent in the cable coating of HF-type electrical cables. Table 6 further comprises Prior Art 2, in which the tape base and adhesive contained no anti-oxidizing agent, but contained, as adhesive adjuvant, a rosin-type resin instead of the foregoing specific resin.
[0214] A third type of the adhesive tape comprised a PVC-type copper damage-preventing adhesive tape (Examples 11 to 15), in which the tape base was formed of a vinyl chloride resin containing a copper damage inhibitor, one face of which was painted with an adhesive that contained an adhesive adjuvant made of a specific resin, and a copper damage inhibitor. Table 7 shows the composition of the PVC-type copper damage-preventing adhesive tapes of Examples 11 to 15.
[0215] The tape base comprised 60 parts by weight of DOP as plasticizer, 20 parts by weight of calcium carbonate as fillers, 5 parts by weight of stabilizer and respectively 0.002, 0.016, 1.6, 4.8 and 8 parts by weight of copper damage inhibitor, relative to 100 parts by weight of PVC (P: 1300). When expressed by weight ratio relative to the organic component (PVC+DOP), the copper damage inhibitors were contained in a ratio of, respectively, 0.001, 0.01, 1, 3 and 5 in the tape base. The tape base had a thickness of 0.11 mm.
[0216] The adhesive of Examples 11 to 15 comprised 70 parts by weight of styrene butadiene rubber, 30 parts by weight of natural rubber and 20 parts by weight of zinc white. Examples 11 to 15 further comprised, as adhesive adjuvant made of a specific resin, 80 parts by weight of, respectively, hydrogenated terpene-type resin, hydrogenated aromatic resin, hydrogenated aliphatic resin, cumarone-indene-type resin and phenol-type resin, as well as, respectively, 0.002, 0.02, 1.8, 4.8 and 9 parts by weight of copper damage inhibitor. The weight ratios of the above copper damage inhibitor corresponded to 0.001, 0.01, 1, 3 and 5, respectively, relative to 100 parts by weight of base organic material portion (styrene-butadiene rubber+natural rubber+specific resin). The adhesive had a thickness of 0.02 mm.
[0217] Table 7 also comprises a Comparative Example 3, in which the ratio of copper damage inhibitor was 7 parts by weight, relative to 100 parts by weight of base organic material portion in the tape base and adhesive, while this ratio was 5 to 100 parts by weight in Example 15. Table 7 further comprises Prior Art 3, in which the tape base and adhesive contained no copper damage inhibitor, but contained, as adhesive adjuvant, a rosin-type resin instead of the foregoing specific resin.
[0218] A fourth type of the adhesive tape comprised a HF-type copper damage-preventing adhesive tape (Examples 16 to 20), in which the tape base was formed of a HF-type resin containing a copper damage inhibitor, one face of which was painted with an adhesive that contained an adhesive adjuvant made of a specific resin, and a copper damage inhibitor. Table 8 shows the composition of the HF-type copper damage-preventing adhesive tapes of Examples 16 to 20.
[0219] The tape base comprised 3 parts by weight of bromine-type flame-retardant, 1.5 parts by weight of antimony trioxide and respectively 0.001, 0.01, 1, 3.1 and 5.2 parts by weight of copper damage inhibitor, relative to 100 parts by weight of polyolefin. When expressed by weight ratio relative to 100 parts by weight of base organic material portion (polyolefin+bromine-type flame-retardant), the copper damage inhibitors were contained in a ratio of, respectively, 0.001, 0.01, 1, 3 and 5 in the tape base. The tape base had a thickness of 0.11 mm.
[0220] The adhesive of Examples 16 to 20 comprised 70 parts by weight of styrene butadiene rubber, 30 parts by weight of natural rubber and 20 parts by weight of zinc white. Examples 16 to 20 further comprised, as adhesive adjuvant made of a specific resin, 80 parts by weight of, respectively, hydrogenated terpene-type resin, hydrogenated aromatic resin, hydrogenated aliphatic resin, cumarone-indene-type resin and phenol-type resin, as well as, respectively, 0.002, 0.02, 1.8, 4.8 and 9 parts by weight of copper damage inhibitor. The weight ratios of the above copper damage inhibitor in the adhesive correspond to 0.001, 0.01, 1, 3 and 5, respectively, relative to 100 parts by weight of base organic material portion (styrene butadiene rubber+natural rubber+specific resin). The adhesive had a thickness of 0.02 mm.
[0221] Table 8 also comprises a Comparative Example 4, in which the ratio of copper damage inhibitor was 7 parts by weight, relative to 100 parts by weight of base organic material portion in the tape base and adhesive, while this ratio was 5 to 100 parts by weight in Example 20. Table 8 further comprises Prior Art 4, in which the tape base and adhesive contained no copper damage inhibitor, but contained, as adhesive adjuvant, a rosin-type resin instead of the foregoing specific resin.
[0222] A fifth type of the adhesive tape comprised a PVC-type, anti-oxidizing and copper damage inhibiting adhesive tape (Examples 21 to 25), in which the tape base was formed of a vinyl chloride resin containing an anti-oxidizing agent and a copper damage inhibitor, one face of which was painted with an adhesive that contained an adhesive adjuvant made of a specific resin, an anti-oxidizing agent and a copper damage inhibitor. Table 9 shows the composition of the PVC-type, anti-oxidizing and copper damage inhibiting adhesive tapes of Examples 21 to 25.
[0223] The tape base comprised 60 parts by weight of DOP as plasticizer, 20 parts by weight of calcium carbonate as fillers, 5 parts by weight of stabilizer, 5 parts by weight of anti-oxidizing agent and respectively 0.002, 0.016, 1.6, 4.8 and 8 parts by weight of copper damage inhibitor, relative to 100 parts by weight of PVC (P: 1300). When expressed by weight ratio relative to 100 parts by weight of base organic material portion (PVC+DOP), the copper damage inhibitors were contained in a ratio of, respectively, 0.001, 0.01, 1, 3 and 5 in the tape base. The weight ratio of anti-oxidizing agent to resin component in the tape base of Examples 21 to 25 was similar to that in the cable coating of HF-type electrical cables (i.e. about 3 parts by weight relative to 100 parts by weight of base organic material portion). The tape base had a thickness of 0.11 mm.
[0224] The adhesive of Examples 21 to 25 comprised 70 parts by weight of styrene butadiene rubber, 30 parts by weight of natural rubber, 20 parts by weight of zinc white and 6 parts by weight of anti-oxidizing agent. Examples 21 to 25 further comprised, as adhesive adjuvant made of a specific resin, 80 parts by weight of, respectively, hydrogenated terpene-type resin, hydrogenated aromatic resin, hydrogenated aliphatic resin, cumarone-indene-type resin and phenol-type resin, as well as, respectively, 0.002, 0.02, 1.8, 4.8 and 9 parts by weight of copper damage inhibitor. The weight ratios of the above copper damage inhibitor correspond to 0.001, 0.01, 1, 3 and 5, respectively, relative to 100 parts by weight of base organic material portion (styrene-butadiene rubber+natural rubber+specific resin). The weight ratio of anti-oxidizing agent to resin component in the adhesive of Examples 21 to 25 was similar to that in the cable coating of HF-type electrical cables (i.e. about 3 parts by weight relative to 100 parts by weight of base organic material portion). The adhesive had a thickness of 0.02 mm.
[0225] Table 9 also comprises a Comparative Example 5, in which the ratio of copper damage inhibitor was 7 parts by weight, relative to 100 parts by weight of base organic material portion in the tape base and adhesive, while this ratio was 5:100 (parts by weight) in Example 25. Table 9 further comprises Prior Art 5, in which the tape base and adhesive contained no anti-oxidizing agent and no copper damage inhibitor, but contained, as adhesive adjuvant, a rosin-type resin instead of the foregoing specific resin.
[0226] A sixth type of the adhesive tape comprised a HF-type, anti-oxidizing and copper damage-inhibiting adhesive tape (Examples 26 to 30), in which the tape base was formed of a HF-type resin containing an anti-oxidizing agent and a copper damage inhibitor, one face of which was painted with an adhesive that contained an adhesive adjuvant made of a specific resin, an anti-oxidizing agent and a copper damage inhibitor. Table 10 shows the composition of the HF-type, anti-oxidizing and copper damage inhibiting adhesive tapes of Examples 26 to 30.
[0227] The tape base comprised 3 parts by weight of bromine-type flame-retardant, 1.5 parts by weight of antimony trioxide, 3.5 parts by weight of anti-oxidizing agent and respectively 0.001, 0.01, 1, 3.1 and 5.2 parts by weight of copper damage inhibitor, relative to 100 parts by weight of polyolefin. When expressed by weight ratio relative to 100 parts by weight of base organic material portion (polyolefin+bromine-type flame-retardant), the copper damage inhibitors were contained in a ratio of, respectively, 0.001, 0.01, 1, 3 and 5 in the tape base. The weight ratio of anti-oxidizing agent to resin component in the tape base of Examples 26 to 30 was similar to that in the cable coating of HF-type electrical cables (i.e. about 3 parts by weight relative to 100 parts by weight of base organic material portion). The tape base had a thickness of 0.11 mm.
[0228] The adhesive of Examples 26 to 30 comprised 70 parts by weight of styrene butadiene rubber, 30 parts by weight of natural rubber, 20 parts by weight of zinc white and 6 parts by weight of anti-oxidizing agent. Examples 26 to 30 further comprised, as adhesive adjuvant made of a specific resin, 80 parts by weight of, respectively, hydrogenated terpene-type resin, hydrogenated aromatic resin, hydrogenated aliphatic resin, cumarone-indene-type resin and phenol-type resin, as well as, respectively, 0.002, 0.02, 1.8, 4.8 and 9 parts by weight of copper damage inhibitor. The weight ratios of the above copper damage inhibitor in the adhesive correspond to 0.001, 0.01, 1, 3 and 5, respectively, relative to 100 parts by weight of base organic material portion (styrene butadiene rubber+natural rubber+specific resin). The weight ratio of anti-oxidizing agent to resin component in the adhesive of Examples 26 to 30 was similar to that in the cable coating of HF-type electrical cables (i.e. about 3 parts by weight relative to 100 parts by weight of base organic material portion) The adhesive had a thickness of 0.02 mm.
[0229] Table 10 also comprised a Comparative Example 6, in which the ratio of copper damage inhibitor was 7 parts by weight, relative to 100 parts by weight of base organic material portion in the tape base and adhesive, while this ratio was 5:100 (parts by weight) in Example 30. Table 10 further comprises Prior Art 6, in which the tape base and adhesive contained no anti-oxidizing agent and no copper damage inhibitor, but contained, as adhesive adjuvant, a rosin-type resin instead of the foregoing specific resin.
[0230] Cable Bundles
[0231] The cable bundle, around which the adhesive tape as harness-protecting material was wrapped, comprised three types.
[0232] A first type relates to a HF-type plain electrical cable, in which 30 HF-type electrical cables were assembled into a cable bundle, and the latter was wrapped with the cable coatings referred to in Table 1.
[0233] A second type relates to a PVC- and HF-type mixed cable bundle, in which there were provided electrical cables wrapped with the cable coatings referred to in Table 1 and those wrapped with the cable coatings referred to in Table 2, and they were assembled in a given mixture ratio, i.e. PVC:HF (by number of cables)=29:1; 20:10 and 1:29.
[0234] A third type relates to a mixed cable bundle of PVC-type anti-oxidizing electrical cables and HF-type electrical cables, in which PVC-type electrical cables covered with the cable coatings (containing an anti-oxidizing agent) referred to in Table 3, and HF-type electrical cables covered with the cable coatings referred to in Table 1 were mixed in a given ratio. The ratio of PVC-type anti-oxidizing electrical cables to HF-type electrical cables (by number of cables) was: 29:1, 20:10 and 1/29.
[0235] When, in the second and third types, only one electrical cable was different from the others, that electrical cable was assembled such that it was placed in contact with the adhesive of the adhesive tape. When the ratio was 20:10, the electrical cables of one type were assembled such that they were well mingled with the electrical cables of another type.
[0236] Wire Harness
[0237] A wire harness was prepared by wrapping the electrical cables with the adhesive tape as a harness-protecting material of the invention. As 6 types of adhesive tape and 3 types of cable bundle were prepared, the wire harnesses produced included 18 sorts of combinations.
[0238] First, the HF-type plain cable bundles were wrapped with PVC-type adhesive tapes (with anti-oxidizing agent) of Examples 1 to 5, to prepare wire harnesses W1 to W5. Second, the HF-type plain cable bundles were wrapped with HF-type adhesive tapes (with anti-oxidizing agent) of Examples 6 to 10, to prepare wire harnesses W6 to W10. Third, the HF-type plain cable bundles were wrapped with PVC-type adhesive tapes (with copper damage inhibitor) of Examples 11 to 15, to prepare wire harnesses W11 to W15. Fourth, the HF-type plain cable bundles were wrapped with HF-type adhesive tapes (with copper damage inhibitor) of Examples 16 to 20, to prepare wire harnesses W16 to W20. Fifth, the HF-type plain cable bundles were wrapped with PVC-type adhesive tapes (with anti-oxidizing agent and copper damage inhibitor) of Examples 21 to 25, to prepare wire harnesses W21 to W25. Sixth, the HF-type plain cable bundles were wrapped with HF-type adhesive tapes (with anti-oxidizing agent and copper damage inhibitor) of Examples 26 to 30, to prepare wire harnesses W26 to W30. Further, the adhesive tapes of Comparative Examples 1 to 6 and of Prior Art 1 to 6 were wrapped around the HF-type plain cable bundles, to prepare the corresponding wire harnesses.
[0239] Likewise, firstly, the mixed cable bundles comprising PVC-type electrical cables and HF-type electrical cables were wrapped with PVC-type adhesive tapes (with anti-oxidizing agent) of Examples 1 to 5, to prepare wire harnesses W31 to W35. Second, the corresponding mixed cable bundles were wrapped with HF-type adhesive tapes (with anti-oxidizing agent) of Examples 6 to 10, to prepare wire harnesses W36 to W40 . Third, the corresponding mixed cable bundles were wrapped with PVC-type adhesive tapes (with copper damage inhibitor) of Examples 11 to 15, to prepare wire harnesses W41 to W45. Fourth, the corresponding mixed cable bundles were wrapped with HF-type adhesive tapes (with copier damage inhibitor) of Examples 16 to 20, to prepare wire harnesses W46 to W50. Fifth, the corresponding mixed cable bundles were wrapped with PVC-type adhesive tapes (with anti-oxidizing agent and copper damage inhibitor) of Examples 21 to 25, to prepare wire harnesses W51 to W55. Sixth, the corresponding mixed cable bundles were wrapped with HF-type adhesive tapes (with anti-oxidizing agent and copper damage inhibitor) of Examples 26 to 30, to prepare wire harnesses W56 to W60. Further, the adhesive tapes of Comparative Examples 1 to 6 and of Prior Art 1 to 6 were wrapped around the mixed cable bundles, to prepare the corresponding wire harnesses.
[0240] Further, firstly, the mixed cable bundles comprising PVC-type electrical cables (with anti-oxidizing agent) and HF-type electrical cables were wrapped with PVC-type adhesive tapes (with anti-oxidizing agent) of Examples 1 to 5, to prepare wire harnesses W61 to W65. Second, the corresponding mixed cable bundles were wrapped with HF-type adhesive tapes (with anti-oxidizing agent) of Examples 6 to 10, to prepare wire harnesses W66 to W70. Third, the corresponding mixed cable bundles were wrapped with PVC-type adhesive tapes (with copper damage inhibitor) of Examples 11 to 15, to prepare wire harnesses W71 to W75. Fourth, the corresponding mixed cable bundles were wrapped with HF-type adhesive tapes (with copper damage inhibitor) of Examples 16 to 20, to prepare wire harnesses W76 to W80. Fifth, the corresponding mixed cable bundles were wrapped with PVC-type adhesive tapes (with anti-oxidizing agent and copper damage inhibitor) of Examples 21 to 25, to prepare wire harnesses W81 to W85. Sixth, the corresponding mixed cable bundles were wrapped with HF-type adhesive tapes (with anti-oxidizing agent and copper damage inhibitor) of Examples 26 to 30, to prepare wire harnesses W86 to W90. Further, the adhesive tapes of Comparative Examples 1 to 6 and of Prior Art 1 to 6 were wrapped around the mixed cable bundles, to prepare the corresponding wire harnesses.
[0241] Test Methods
[0242] The wire harnesses thus prepared were subjected to various tests as follows. Each wire harness was allowed to stand in a thermostat at 150° C. for 96 hours. The wire harness was then withdrawn from the thermostat and the adhesive tape was stripped off the wire harness. The electrical cables in each cable bundle were wound around a mandrel of Φ 10 mm, and visually observed whether cracks were formed in the cable coatings. Likewise, when preparing wire harness, the adhesive tape was wrapped around the cable bundle and the ease of wrapping operation was evaluated. Further, when preparing the adhesive tape, the gluing capacity of the adhesive was evaluated. When the copper damage inhibitor was added to the adhesive tape, the appearance of the tape was also observed.
[0243] Test Results
[0244] (1) HF-Type Plain Cable Bundle×PVC-Type Adhesive Tape (with Anti-Oxidizing Agent)
[0245] The HF-type plain cable bundle was wrapped with a PVC-type adhesive tape (with anti-oxidizing agent) to form a wire harness, which was indicated as “HF-type plain cable bundle×PVC-type adhesive tape (with anti-oxidizing agent)”. The other wire harnesses were also indicated in the same manner, unless otherwise mentioned.
[0246] Table 11 shows the results of the tests carried out with a HF-type plain cable bundle×PVC-type adhesive tape (with anti-oxidizing agent). As to the winding test, cracks were found in the HF-type electrical cables in Prior Art W1 (wire harness), and the latter were evaluated as defective. It was understood that the adhesive-side deterioration accelerators and the tape base-side deterioration accelerators moved into the cable coatings of HF-type electrical cables, thereby causing the copper damage and decrease in anti-oxidizing agent in the cable coatings.
[0247] By comparison, the HF-type electrical cables in wire harnesses of Examples W1 to W5 did not form any crack by the mandrel-winding tests. In the above preparation, the PVC-type adhesive tapes (with anti-oxidizing agent) of Examples 1 to 5 were supplied with an adhesive adjuvant made of a low-reactivity specific resin hardly prone to bond with other atoms and molecules, so that the copper damage, due to the migration of adhesive adjuvant, was at least prevented. Further, as the adhesive and tape base contains an anti-oxidizing agent in a suitable amount, the decrease in anti-oxidizing agent of the cable coatings, caused by the migration of adhesive-side deterioration accelerators and tape base-side deterioration accelerators, was prevented.
[0248] As to the ease of wrapping operation and gluing capacity, the PVC-type adhesive tape (with anti-oxidizing agent) of Comparative Example 1 was judged as defective, the reason for this deficiency being probably that it contained an excess quantity of anti-oxidizing agent. By comparison, the PVC-type adhesive tapes (with anti-oxidizing agent) of Examples 1 to 5 were found good in ease of wrapping operation and gluing capacity, the reason therefor being probably that they contained the anti-oxidizing agent in a suitable amount. The Examples of the invention were evaluated as globally good (indicated by “O” in Tables)
[0249] (2) HF-Type Plain Cable Bundle×HF-Type Adhesive Tape (with Anti-Oxidizing Agent).
[0250] Table 12 shows the results of the tests effected with the HF-type plain cable bundle×HF-type adhesive tape (with anti-oxidizing agent). According to the mandrel-winding tests, the HF-type electrical cables in the wire harness of Prior Art W2 formed cracks and were found defective. This is probably because the adhesive-side deterioration accelerators and tape base-side deterioration accelerators moved into the cable coatings of HF-type electrical cables, thereby causing the copper damage and decrease in anti-oxidizing agent in the cable coatings.
[0251] The HF-type adhesive tape itself of Prior Art 2 formed cracks probably because the adhesive-side deterioration accelerators moved into the tape base. This adhesive tape was thus found defective.
[0252] The HF-type electrical cables in the wire harnesses of Examples W6 to W10 formed no crack by the mandrel-winding tests. In the above preparation, the HF-type adhesive tapes (with anti-oxidizing agent) of Examples 6 to 10 were supplied with an adhesive adjuvant made of a low-reactivity specific resin hardly prone to bond with other atoms and molecules, so that the copper damage, due to the migration of adhesive adjuvant, was at least prevented. Further, as the adhesive and tape base contains an anti-oxidizing agent in a suitable amount, the decrease in anti-oxidizing agent of the cable coatings, caused by the migration of adhesive-side deterioration accelerators and tape base-side deterioration accelerators, was prevented.
[0253] As to the ease of wrapping operation and gluing capacity, HF-type adhesive tape (with anti-oxidizing agent) of Comparative Example 2 was judged as defective, the reason therefor being probably that it contained an excess of anti-oxidizing agent. By comparison, the HF-type adhesive tapes (with anti-oxidizing agent) of Examples 6 to 10 were found good in ease of wrapping operation and gluing capacity, the reason for this being probably that they contained the anti-oxidizing agent in a suitable amount. The Examples of the invention were evaluated as globally good (“O”).
[0254] (3) HF-Type Plain Cable Bundle×PVC-Type Adhesive Tape (with Copper Damage Inhibitor)
[0255] Table 13 shows the results of the tests effected with the HF-type plain cable bundle×PVC-type adhesive tape (with copper damage inhibitor). According to the mandrel-winding tests, the HF-type electrical cables in the wire harness of Prior Art W3 formed cracks and were found defective. This is probably because the adhesive-side deterioration accelerators and tape base-side deterioration accelerators moved into the cable coatings of HF-type electrical cables, thereby causing the copper damage and decrease in anti-oxidizing agent in the cable coatings.
[0256] The HF-type electrical cables in the wire harnesses of Examples W11 to W15 formed no crack by the mandrel-winding tests. In the above preparation, the PVC-type adhesive tapes (with copper damage inhibitor) of Examples 11 to 15 were supplied with an adhesive adjuvant made of a low-reactivity specific resin hardly prone to bond with other atoms and molecules, so that the copper damage, due to the migration of adhesive adjuvant, was at least prevented. Further, the adhesive and tape base contained a copper damage inhibitor in a suitable amount. Accordingly, although the copper damage inhibitor was consumed by the migration of the adhesive-side deterioration accelerators and tape base-side deterioration accelerators other than the adhesive adjuvant, fresh copper damage inhibitor was supplied from the adhesive tape into the cable coatings, and the copper damage was securely prevented.
[0257] As to the ease of wrapping operation, tape appearance and gluing capacity, the PVC-type adhesive tape (with copper damage inhibitor) of Comparative Example 3 was judged as defective, the reason for this being probably that it contained an excessive copper damage inhibitor. By comparison, the PVC-type adhesive tapes (with copper damage inhibitor) of Examples 11 to 15 were found good in ease of wrapping operation, tape appearance and gluing capacity, the reason for this being probably that they contained the copper damage inhibitor in a suitable amount. The Examples of the invention were evaluated as globally good (“O”).
[0258] (4) HF-Type Plain Cable Bundle×HF-Type Adhesive Tape (with Copper Damage Inhibitor)
[0259] Table 14 shows the results of the tests effected with the HF-type plain cable bundle×HF-type adhesive tape (with copper damage inhibitor). According to the mandrel-winding tests, the HF-type electrical cables in the wire harness of Prior Art W4 formed cracks and were found defective. This is probably because the adhesive-side deterioration accelerators and tape base-side deterioration accelerators moved into the cable coatings of HF-type electrical cables, thereby causing the copper damage and decrease in anti-oxidizing agent in the cable coatings.
[0260] The HF-type adhesive tape itself of Prior Art 4 formed cracks probably because the adhesive-side deterioration accelerators moved into the tape base. This adhesive tape was thus found defective.
[0261] The HF-type electrical cables in the wire harnesses of Examples W16 to W20 formed no crack by the mandrel-winding tests. In the above preparation, the HF-type adhesive tapes (with copper damage inhibitor) of Examples 16 to 20 were supplied with an adhesive adjuvant made of a low-reactivity specific resin hardly prone to bond with other atoms and molecules, so that the copper damage, due to the migration of adhesive adjuvant, was at least prevented. Further, the adhesive and tape base contained a copper damage inhibitor in a suitable amount. Accordingly, although the copper damage inhibitor was consumed by the migration of the adhesive-side deterioration accelerators and tape base-side deterioration accelerators other than the adhesive adjuvant, fresh copper damage inhibitor was supplied from the adhesive tape into the cable coatings, and the copper damage could be securely prevented.
[0262] As to the ease of wrapping operation, tape appearance and gluing capacity, the HF-type adhesive tape (with copper damage inhibitor) of Comparative Example 4 was judged as defective, the reason for this being probably that it contained an excessive copper damage inhibitor. By comparison, the HF-type adhesive tapes (with copper damage inhibitor) of Examples 16 to 20 were found good in ease of wrapping operation, tape appearance and gluing capacity, the reason for this being probably that they contained the copper damage inhibitor in a suitable amount. The Examples of the invention were evaluated as globally good (“O”).
[0263] (5) HF-Type Plain Cable Bundle×PVC-Type Adhesive Tape (with Anti-Oxidizing Agent and Copper Damage Inhibitor)
[0264] Table 15 shows the results of the tests effected with the HF-type plain cable bundle×PVC-type adhesive tape (with anti-oxidizing agent and copper damage inhibitor). According to the mandrel-winding tests, the HF-type electrical cables in the wire harness of Prior Art W5 formed cracks and were found defective. It is probably because the adhesive-side deterioration accelerators and tape base-side deterioration accelerators moved into the cable coatings of HF-type electrical cables, thereby causing the copper damage and decrease in anti-oxidizing agent of the cable coatings.
[0265] The HF-type electrical cables in the wire harnesses of Examples W21 to W25 formed no crack by the mandrel-winding tests. The use of a specific resin as adhesive adjuvant in the adhesive, as well as the presence of anti-oxidizing agent and copper damage inhibitor in the adhesive and tape base in a suitable amount, produced a synergic effect. In this manner, the decrease of the anti-oxidizing agent in the cable coatings and the copper damage due to copper ions could thus be prevented efficiently.
[0266] As to the ease of wrapping operation, tape appearance and gluing capacity, the PVC-type adhesive tape (with anti-oxidizing agent and copper damage inhibitor) of Comparative Example 5 was judged as defective, the reason for this being probably that it contained an excessive copper damage inhibitor. By comparison, the PVC-type adhesive tapes (with anti-oxidizing agent and copper damage inhibitor) of Examples 21 to 25 were found good in ease of wrapping operation, tape appearance and gluing capacity, the reason therefor being that they contained the anti-oxidizing agent and copper damage inhibitor in a suitable amount. The Examples of the invention were evaluated as globally good (“O”).
[0267] (6) HF-Type Plain Cable Bundle×HF-Type Adhesive Tape (with Anti-Oxidizing Agent and Copper Damage Inhibitor)
[0268] Table 16 shows the results of the tests effected with the HF-type plain cable bundle×HF-type adhesive tape (with anti-oxidizing agent and copper damage inhibitor). According to the mandrel-winding tests, the HF-type electrical cables in the wire harness of Prior Art W6 formed cracks and were found defective. This is because the adhesive-side deterioration accelerators and tape base-side deterioration accelerators moved into the cable coatings of HF-type electrical cables, thereby causing the copper damage and decrease in anti-oxidizing agent in the cable coatings.
[0269] The HF-type adhesive tape itself of Prior Art 6 formed cracks, because the adhesive-side deterioration accelerators moved into the tape base.
[0270] The HF-type electrical cables in the wire harnesses of Examples W26 to W30 formed no crack by the mandrel-winding tests. The use of a specific resin as adhesive adjuvant in the adhesive, as well as the presence of anti-oxidizing agent and copper damage inhibitor in the adhesive and tape base in a suitable amount, produced a synergic effect. In this manner, the decrease of the anti-oxidizing agent in cable coatings and the copper damage due to copper ions could be prevented efficiently.
[0271] As to the ease of wrapping operation, tape appearance and gluing capacity, the HF-type adhesive tape (with anti-oxidizing agent and copper damage inhibitor) of Comparative Example 6 was judged as defective, the reason therefor being that it contained an excessive quantity of copper damage inhibitor. By comparison, the HF-type adhesive tapes (with anti-oxidizing agent and copper damage inhibitor) of Examples 26 to 30 were found good in ease of wrapping operation, tape appearance and gluing capacity, the reason for this being that they contained the anti-oxidizing agent and copper damage inhibitor in a suitable amount. The Examples of the invention were evaluated as globally good (“G”).
[0272] (7) (Mixed Cable Bundle of PVC-Type Electrical Cables and HF-Type Electrical Cables)×PVC-Type Adhesive Tape (with Anti-Oxidizing Agent)
[0273] Table 17 shows the results of the tests carried out with a (mixed cable bundle of PVC-type electrical cables and HF-type electrical cables)×PVC-type adhesive tape (with anti-oxidizing agent). As to the mandrel-winding test, cracks were found in the HF-type electrical cables in the wire harness (cable number ratio of 29:1, 20:10 and 1:29) of Prior Art W7, and the latter was evaluated as defective. It was understood that the adhesive-side deterioration accelerators and the tape base-side deterioration accelerators moved into the cable coatings of HF-type electrical cables, thereby causing the copper damage and decrease of anti-oxidizing agent in the cable coatings.
[0274] In particular, when the cable number ratio of PVC-type electrical cables and HF-type electrical cables was 29:1, the deterioration of the HF-type electrical cable tended to be very drastic. This may be caused by the fact that the plasticizer and the like contained in the cable coatings of PVC-type electrical cables moved into the coatings of HF-type electrical cables.
[0275] By comparison, the HF-type electrical cables in wire harnesses of Examples W31 to W35 did not form any crack by the mandrel-winding tests. In the above preparation, the PVC-type adhesive tapes (with anti-oxidizing agent) of Examples 1 to 5 were supplied with an adhesive adjuvant made of a low-reactivity specific resin hardly prone to bond with other atoms and molecules, so that the copper damage, due to the migration of adhesive adjuvant was at least prevented. Further, as the adhesive and tape base contains an anti-oxidizing agent in a suitable amount, the decrease of the anti-oxidizing agent in the cable coatings caused by the migration of adhesive-side deterioration accelerators and tape base-side deterioration accelerators, was prevented.
[0276] However, in this case also, the plasticizers and the like contained in the cable coatings of PVC-type electrical cables may move into the cable coatings of HF-type electrical cables, thereby causing the deterioration of the HF-type electrical cables due to the agent migration between the electrical cables. The fact that this did not happen in the Examples of the invention indicates that the anti-oxidizing agent in the PVC-type adhesive tape moved into the cable coatings of HF-type electrical cables, thereby supplying the anti-oxidizing agent to the cable coatings.
[0277] As to the ease of wrapping operation and gluing capacity, the PVC-type adhesive tape (with anti-oxidizing agent) of Comparative Example 1 was judged as defective, the reason for this deficiency being probably that it contained an excess amount of anti-oxidizing agent. By comparison, the PVC-type adhesive tapes (with anti-oxidizing agent) of Examples 1 to 5 were found good in ease of wrapping operation and gluing capacity, the reason for this being that they contained the anti-oxidizing agent in a suitable amount. The Examples of the invention were evaluated as globally good (indicated by “O” in Tables)
[0278] (8) (Mixed Cable Bundle of PVC-Type Electrical Cables and HF-Type Electrical Cables)×HF-Type Adhesive Tape (with Anti-Oxidizing Agent)
[0279] Table 18 shows the results of the tests carried out with a (mixed cable bundle of PVC-type electrical cables and HF-type electrical cables)×HF-type adhesive tape (with anti-oxidizing agent). As to the mandrel-winding test, cracks were found in the HF-type electrical cables in the wire harness (cable number ratio of 29:1, 20:10 and 1:29) of Prior Art W8, and the latter was evaluated as defective. It was understood that the adhesive-side deterioration accelerators and the tape base-side deterioration accelerators moved into the cable coatings of HF-type electrical cables, thereby causing the copper damage and decrease of anti-oxidizing agent in the cable coatings.
[0280] In particular, when the cable number ratio of PVC-type electrical cables and HF-type electrical cables was 29:1, the deterioration of the HF-type electrical cable tended to be very strong. This may be caused by the fact that the plasticizer and the like contained in the cable coatings of PVC-type electrical cables moved into the coatings of HF-type electrical cables.
[0281] Further, the HF-type adhesive tape itself of Prior Art 2 formed cracks, and was judged defective. This cracking was caused by the fact that the adhesive-side deterioration accelerators moved into the tape base.
[0282] By comparison, the HF-type electrical cables in wire harnesses of Examples W36 to W40 did not form any crack by the mandrel-winding tests. In the above preparation, the HF-type adhesive tapes (with anti-oxidizing agent) of Examples 6 to 10 were supplied with an adhesive adjuvant made of a low-reactivity specific resin hardly prone to bond with other atoms and molecules, so that the copper damage, due to the migration of adhesive adjuvant, was at least prevented. Further, as the adhesive and tape base contains an anti-oxidizing agent in a suitable amount, the decrease of the anti-oxidizing agent in the cable coatings, caused by the migration of adhesive-side deterioration accelerators and tape base-side deterioration accelerators, was prevented.
[0283] However, in this case also, the plasticizers and the like contained in the cable coatings of PVC-type electrical cables may move into the cable coatings of HF-type electrical cables, thereby causing the deterioration of the HF-type electrical cables due to the agent migration between the electrical cables. The fact that this did not happen in the Examples of the invention indicates that the anti-oxidizing agent in the HF-type adhesive tape moved into the cable coatings of HF-type electrical cables, thereby supplying the anti-oxidizing agent to the cable coatings.
[0284] As to the ease of wrapping operation and gluing capacity, the HF-type adhesive tape (with anti-oxidizing agent) of Comparative Example 2 was judged as defective, the reason for this deficiency being probably that it contained an excess amount of anti-oxidizing agent. By comparison, the HF-type adhesive tapes (with anti-oxidizing agent) of Examples 6 to 10 were found good in ease of wrapping operation and gluing capacity, the reason for this being that they contained the anti-oxidizing agent in a suitable amount. The Examples of the invention were evaluated as globally good (indicated by “O” in Tables)
[0285] (9) (Mixed Cable Bundle of PVC-Type Electrical Cables and HF-Type Electrical Cables)×PVC-Type Adhesive Tape (with Copper Damage Inhibitor)
[0286] Table 19 shows the results of the tests carried out with a (mixed cable bundle of PVC-type electrical cables and HF-type electrical cables)×PVC-type adhesive tape (with copper damage inhibitor). As to the mandrel-winding test, cracks were found in the HF-type electrical cables in the wire harness (cable number ratio of 29:1, 20:10 and 1:29) of Prior Art W9, and the latter was evaluated as defective. It was understood that the adhesive-side deterioration accelerators and the tape base-side deterioration accelerators moved into the cable coatings of HF-type electrical cables, thereby causing the copper damage and decrease of anti-oxidizing agent in the cable coatings.
[0287] In particular, when the cable number ratio of PVC-type electrical cables and HF-type electrical cables was 29: 1, the deterioration of the HF-type electrical cable tended to be very strong. This may be caused by the fact that the plasticizer and the like contained in the cable coatings of PVC-type electrical cables moved into the coatings of HF-type electrical cables.
[0288] By comparison, the HF-type electrical cables in wire harnesses of Examples W41 to W45 did not form any crack by the mandrel-winding tests. In the above preparation, the PVC-type adhesive tapes (with copper damage inhibitor) of Examples 11 to 15 were supplied with an adhesive adjuvant made of a low-reactivity specific resin hardly prone to bond with other atoms and molecules, so that the copper damage, due to the migration of adhesive adjuvant, was at least prevented. Further, the adhesive and tape base contained a copper damage inhibitor in a suitable amount. Accordingly, when the copper damage inhibitor was consumed by the migration of the adhesive-side deterioration accelerators and tape base-side deterioration accelerators other than the adhesive adjuvant, a fresh copper damage inhibitor was supplied from the adhesive tape to the cable coatings. The copper damage could thus be securely avoided.
[0289] However, in this case also, the plasticizers and the like contained in the cable coatings of PVC-type electrical cables may move into the cable coatings of HF-type electrical cables, thereby causing the deterioration of the HF-type electrical cables due to the agent migration between the electrical cables. The fact that this did not happen in the Examples of the invention indicates that the copper damage inhibitor in the PVC-type adhesive tape moved into the cable coatings of HF-type electrical cables, thereby supplying the copper damage inhibitor to the cable coatings.
[0290] As to the ease of wrapping operation, tape appearance and gluing capacity, the PVC-type adhesive tape (with copper damage inhibitor) of Comparative Example 3 was judged as defective, the reason for this deficiency being probably that it contained an excess amount of copper damage inhibitor. By comparison, the PVC-type adhesive tapes (with copper damage inhibitor) of Examples 11 to 15 were found good in ease of wrapping operation, tape appearance and gluing capacity, the reason for this being that they contained the copper damage inhibitor in a suitable amount. The Examples of the invention were evaluated as globally good (indicated by “O” in Tables).
[0291] (10) (Mixed Cable Bundle of PVC-Type Electrical Cables and HF-Type Electrical Cables)×HF-Type Adhesive Tape (with Copper Damage Inhibitor)
[0292] Table 20 shows the results of the tests carried out with a (mixed cable bundle of PVC-type electrical cables and HF-type electrical cables)×HF-type adhesive tape (with copper damage inhibitor). As to the mandrel-winding test, cracks were found in the HF-type electrical cables in the wire harness (cable number ratio of 29:1, 20:10 and 1:29) of Prior Art W10, and the latter was evaluated as defective. It was understood that the adhesive-side deterioration accelerators and the tape base-side deterioration accelerators moved into the cable coatings of HF-type electrical cables, thereby causing the copper damage and decrease of anti-oxidizing agent in the cable coatings.
[0293] In particular, when the cable number ratio of PVC-type electrical cables and HF-type electrical cables was 29:1, the deterioration of the HF-type electrical cable tended to be very strong. This may be caused by the fact that the plasticizer and the like contained in the cable coatings of PVC-type electrical cables moved into the cable coatings of HF-type electrical cables.
[0294] Further, the HF-type adhesive tape itself of Prior Art 4 formed cracks, and was judged defective. This cracking was caused by the fact that the adhesive-side deterioration accelerators moved into the tape base.
[0295] By comparison, the HF-type electrical cables in wire harnesses of Examples W46 to W50 did not form any crack by the mandrel-winding tests. In the above preparation, the HF-type adhesive tapes (with copper damage inhibitor) of Examples 16 to 20 were supplied with an adhesive adjuvant made of a low-reactivity specific resin hardly prone to bond with other atoms and molecules, so that the copper damage, due to the migration of adhesive adjuvant, was at least prevented. Further, the adhesive and tape base contains a copper damage inhibitor in a suitable amount. Accordingly, when the copper damage inhibitor was consumed by the migration of the adhesive-side deterioration accelerators and tape base-side deterioration accelerators other than the adhesive adjuvant, a fresh copper damage inhibitor was supplied from the adhesive tape to the cable coatings. The copper damage could thus be securely avoided.
[0296] However, in this case also, the plasticizers and the like contained in the cable coatings of PVC-type electrical cables may move into the cable coatings of HF-type electrical cables, thereby causing the deterioration of the HF-type electrical cables due to the agent migration between the electrical cables. The fact that this did not happen in the Examples of the invention indicates that the copper damage inhibitor in the HF-type adhesive tape moved into the cable coatings of HF-type electrical cables, thereby supplying the copper damage inhibitor to the cable coatings.
[0297] As to the ease of wrapping operation, tape appearance and gluing capacity, the HF-type adhesive tape (with copper damage inhibitor) of Comparative Example 4 was judged as defective, the reason for this deficiency being probably that it contained an excess amount of copper damage inhibitor. By comparison, the HF-type adhesive tapes (with copper damage inhibitor) of Examples 16 to 20 were found good in ease of wrapping operation, tape appearance and gluing capacity, the reason for this being that they contained the copper damage inhibitor in a suitable amount. The Examples of the invention were evaluated as globally good (indicated by “O” in Tables).
[0298] (11) (Mixed Cable Bundle of PVC-Type Electrical Cables and HF-Type Electrical Cables)×PVC-Type Adhesive Tape (with Anti-Oxidizing Agent and Copper Damage Inhibitor)
[0299] Table 21 shows the results of the tests carried out with a (mixed cable bundle of PVC-type electrical cables and HF-type electrical cables)×PVC-type adhesive tape (with anti-oxidizing agent and copper damage inhibitor). As to the mandrel-winding test, cracks were found in the HF-type electrical cables in the wire harness (cable number ratio of 29:1, 20:10 and 1:29) of Prior Art W11, and the latter was evaluated as defective. It was understood that the adhesive-side deterioration accelerators and the tape base-side deterioration accelerators moved into the cable coatings of HF-type electrical cables, thereby causing the copper damage and decrease of anti-oxidizing agent in the cable coatings.
[0300] In particular, when the cable number ratio of PVC-type electrical cables and HF-type electrical cables was 29:1, the deterioration of the HF-type electrical cable tended to be very strong. This may be caused by the fact that the plasticizer and the like contained in the cable coatings of PVC-type electrical cables moved into the coatings of HF-type electrical cables.
[0301] By comparison, the HF-type electrical cables in wire harnesses of Examples W51 to W55 did not form any crack by the mandrel-winding tests. The use of a specific resin as adhesive adjuvant in the adhesive, as well as the presence of anti-oxidizing agent and copper damage inhibitor in the adhesive and tape base in a suitable amount, produced a synergic effect. In this manner, the decrease of the anti-oxidizing agent in cable coatings and the copper damage due to copper ions could be prevented efficiently.
[0302] However, in this case also, the plasticizers and the like contained in the cable coatings of PVC-type electrical cables may move into the cable coatings of HF-type electrical cables, thereby causing the deterioration of the HF-type electrical cables due to the agent migration between the electrical cables. The fact that this did not happen in the Examples of the invention indicates that the anti-oxidizing agent and copper damage inhibitor in the PVC-type adhesive tape moved into the cable coatings of HF-type electrical cables, thereby supplying the anti-oxidizing agent and copper damage inhibitor to the cable coatings.
[0303] As to the ease of wrapping operation, tape appearance and gluing capacity, the PVC-type adhesive tape (with anti-oxidizing agent and copper damage inhibitor) of Comparative Example 5 was judged as defective, the reason for this deficiency being probably that it contained an excess amount of copper damage inhibitor. By comparison, the PVC-type adhesive tapes (with anti-oxidizing agent and copper damage inhibitor) of Examples 21 to 25 were found good in ease of wrapping operation, tape appearance and gluing capacity, the reason for this being that they contained the anti-oxidizing agent and copper damage inhibitor in a suitable amount. The Examples of the invention were evaluated as globally good (indicated by “O” in Tables)
[0304] (12) (Mixed Cable Bundle of PVC-Type Electrical Cables and HF-Type Electrical Cables)×HF-Type Adhesive Tape (with Anti-Oxidizing Agent and Copper Damage Inhibitor)
[0305] Table 22 shows the results of the tests carried out with a (mixed cable bundle of PVC-type electrical cables and HF-type electrical cables)×HF-type adhesive tape (with anti-oxidizing agent and copper damage inhibitor). As to the mandrel-winding test, cracks were found in the HF-type electrical cables in the wire harness (cable number ratio of 29:1, 20:10 and 1:29) of Prior Art W12, and the latter was evaluated as defective. It was understood that the adhesive-side deterioration accelerators and the tape base-side deterioration accelerators moved into the cable coatings of HF-type electrical cables, thereby causing the copper damage and decrease of anti-oxidizing agent in the cable coatings.
[0306] In particular, when the cable number ratio of PVC-type electrical cables and HF-type electrical cables was 29:1, the deterioration of the HF-type electrical cable tended to be very strong. This may be caused by the fact that the plasticizer and the like contained in the cable coatings of PVC-type electrical cables moved into the cable coatings of HF-type electrical cables.
[0307] Further, the HF-type adhesive tape itself of Prior Art 6 formed cracks, and was judged defective. This cracking was caused by the fact that the adhesive-side deterioration accelerators moved into the tape base.
[0308] By comparison, the HF-type electrical cables in wire harnesses of Examples W56 to W60 did not form any crack by the mandrel-winding tests. The use of a specific resin as adhesive adjuvant in the adhesive, as well as the presence of anti-oxidizing agent and copper damage inhibitor in the adhesive and tape base in a suitable amount, produced a synergic effect. In this manner, the decrease of the anti-oxidizing agent in cable coatings and the copper damage due to copper ions could be prevented efficiently.
[0309] However, in this case also, the plasticizers and the like contained in the cable coatings of PVC-type electrical cables may move into the cable coatings of HF-type electrical cables, thereby causing the deterioration of the HF-type electrical cables due to the agent migration between the electrical cables. The fact that this did not happen in the Examples of the invention indicates that the anti-oxidizing agent and copper damage inhibitor in the HF-type adhesive tape moved into the cable coatings of HF-type electrical cables, thereby supplying the anti-oxidizing agent and copper damage inhibitor to the cable coatings.
[0310] As to the ease of wrapping operation, tape appearance and gluing capacity, the HF-type adhesive tape (with anti-oxidizing agent and copper damage inhibitor) of Comparative Example 6 was judged as defective, the reason for this deficiency being probably that it contained an excess amount of copper damage inhibitor. By comparison, the HF-type adhesive tapes (with anti-oxidizing agent and copper damage inhibitor) of Examples 26 to 30 were found good in ease of wrapping operation, tape appearance and gluing capacity, the reason for this being that they contained the anti-oxidizing agent and copper damage inhibitor in a suitable amount. The Examples of the invention were evaluated as globally good (indicated by “O” in Tables).
[0311] (13) [Mixed Cable Bundle of PVC-Type Electrical Cables (with Anti-Oxidizing Agent) and HF-Type Electrical Cables]×PVC-Type Adhesive Tape (with Anti-Oxidizing Agent)
[0312] Table 23 shows the results of the tests carried out with a (mixed cable bundle of PVC-type electrical cables (with anti-oxidizing agent) and HF-type electrical cables)×PVC-type adhesive tape (with anti-oxidizing agent). As to the mandrel-winding test, cracks were found in the HF-type electrical cables in the wire harness (cable number ratio of 29:1, 20:10 and 1:29) of Prior Art W13, and the latter was evaluated as defective. It was understood that the adhesive-side deterioration accelerators and the tape base-side deterioration accelerators moved into the cable coatings of HF-type electrical cables, thereby causing the copper damage and decrease of anti-oxidizing agent in the cable coatings.
[0313] By comparison, the HF-type electrical cables in wire harnesses of Examples W61 to W65 did not form any crack by the mandrel-winding tests. In the above preparation, the PVC-type adhesive tapes (with anti-oxidizing agent) of Examples 1 to 5 were supplied with an adhesive adjuvant made of a low-reactivity specific resin hardly prone to bond with other atoms and molecules, so that the copper damage, due to the migration of adhesive adjuvant, was at least prevented. Further, as the adhesive and tape base contains an anti-oxidizing agent in a suitable amount, the decrease of the anti-oxidizing agent in the cable coatings, caused by the migration of adhesive-side deterioration accelerators and tape base-side deterioration accelerators, was prevented.
[0314] Moreover, in the present Examples, PVC-type electrical cables containing an anti-oxidizing agent were used. Accordingly, even if the plasticizers and the like contained in the cable coatings of PVC-type electrical cables moved into the cable coatings of HF-type electrical cables, the deterioration of the cable coatings of HF-type electrical cables, owing to the agent migration between the electrical cables, could be efficiently prevented.
[0315] As to the ease of wrapping operation and gluing capacity, the PVC-type adhesive tape (with anti-oxidizing agent) of Comparative Example 1 was judged as defective, the reason for this deficiency being probably that it contained an excess amount of anti-oxidizing agent. By comparison, the PVC-type adhesive tapes (with anti-oxidizing agent) of Examples 1 to 5 were found good in ease of wrapping operation and gluing capacity, the reason for this being that they contained the anti-oxidizing agent in a suitable amount. The Examples of the invention were evaluated as globally good (indicated by “O” in Tables).
[0316] (14) [Mixed Cable Bundle of PVC-Type Electrical Cables (with Anti-Oxidizing Agent) and HF-Type Electrical Cables]×HF-Type Adhesive Tape (with Anti-Oxidizing Agent)
[0317] Table 24 shows the results of the tests carried out with a (mixed cable bundle of PVC-type electrical cables (with anti-oxidizing agent) and HF-type electrical cables)×HF-type adhesive tape (with anti-oxidizing agent). As to the mandrel-winding test, cracks were found in the HF-type electrical cables in the wire harness (cable number ratio of 29:1, 20:10 and 1:29) of Prior Art W14, and the latter was evaluated as defective. It was understood that the adhesive-side deterioration accelerators and the tape base-side deterioration accelerators moved into the cable coatings of HF-type electrical cables, thereby causing the copper damage and decrease of anti-oxidizing agent in the cable coatings.
[0318] Further, the HF-type adhesive tape itself of Prior Art 2 formed cracks, and was judged as failed. This cracking was caused by the migration of the adhesive-side deterioration accelerators into the tape base.
[0319] By comparison, the HF-type electrical cables in wire harnesses of Examples W66 to W70 did not form any crack by the mandrel-winding tests. In the above preparation, the HF-type adhesive tapes (with anti-oxidizing agent) of Examples 6 to 10 were supplied with an adhesive adjuvant made of a low-reactivity specific resin hardly prone to bond with other atoms and molecules, so that the copper damage, due to the migration of adhesive adjuvant, was at least prevented. Further, as the adhesive and tape base contains an anti-oxidizing agent in a suitable amount, the decrease of the anti-oxidizing agent in the cable coatings, caused by the migration of adhesive-side deterioration accelerators and tape base-side deterioration accelerators, was prevented.
[0320] Moreover, in the present Examples, PVC-type electrical cables containing an anti-oxidizing agent were used. Accordingly, even if the plasticizers and the like contained in the cable coatings of PVC-type electrical cables moved into the cable coatings of HF-type electrical cables, the deterioration of the cable coatings of HF-type electrical cables, owing to the agent migration between the electrical cables, could be efficiently prevented.
[0321] As to the ease of wrapping operation and gluing capacity, the HF-type adhesive tape (with anti-oxidizing agent) of Comparative Example 2 was judged as defective, the reason for this deficiency being probably that it contained an excess amount of anti-oxidizing agent. By comparison, the HF-type adhesive tapes (with anti-oxidizing agent) of Examples 6 to 10 were found good in ease of wrapping operation and gluing capacity, the reason for this being that they contained the anti-oxidizing agent in a suitable amount. The Examples of the invention were evaluated as globally good (indicated by “O” in Tables).
[0322] (15) [Mixed Cable Bundle of PVC-Type Electrical Cables (with Anti-Oxidizing Agent) and HF-Type Electrical Cables]×PVC-Type Adhesive Tape (with Copper Damage Inhibitor)
[0323] Table 25 shows the results of the tests carried out with a (mixed cable bundle of PVC-type electrical cables (with anti-oxidizing agent) and HF-type electrical cables)×PVC-type adhesive tape (with copper damage inhibitor). As to the mandrel-winding test, cracks were found in the HF-type electrical cables in the wire harness (cable number ratio of 29:1, 20:10 and 1:29) of Prior Art W15, and the latter was evaluated as defective. It was understood that the adhesive-side deterioration accelerators and the tape base-side deterioration accelerators moved into the cable coatings of HF-type electrical cables, thereby causing the copper damage and decrease of anti-oxidizing agent in the cable coatings.
[0324] By comparison, the HF-type electrical cables in wire harnesses of Examples W71 to W75 did not form any crack by the mandrel-winding tests. In the above preparation, the PVC-type adhesive tapes (with copper damage inhibitor) of Examples 11 to 15 were supplied with an adhesive adjuvant made of a low-reactivity specific resin hardly prone to bond with other atoms and molecules, so that the copper damage, due to the migration of adhesive adjuvant, was at least prevented. Further, the adhesive and tape base contains an anti-oxidizing agent in a suitable amount. Accordingly, when the copper damage inhibitor was consumed by the migration of the adhesive-side deterioration accelerators and tape base-side deterioration accelerators other than the adhesive adjuvant, a fresh copper damage inhibitor was supplied from the adhesive tape to the cable coatings. The copper damage could thus be securely avoided.
[0325] Moreover, in the present Examples, PVC-type electrical cables containing an anti-oxidizing agent were used. Accordingly, even if the plasticizers and the like contained in the cable coatings of PVC-type electrical cables moved into the cable coatings of HF-type electrical cables, the deterioration of the cable coatings of HF-type electrical cables, owing to the agent migration between the electrical cables, could be efficiently prevented.
[0326] As to the ease of wrapping operation, tape appearance and gluing capacity, the PVC-type adhesive tape (with copper damage inhibitor) of Comparative Example 3 was judged as defective, the reason for this deficiency being probably that it contained an excess amount of copper damage inhibitor. By comparison, the PVC-type adhesive tapes (with copper damage inhibitor) of Examples 11 to 15 were found good in ease of wrapping operation, tape appearance and gluing capacity, the reason therefor being that they contained the copper damage inhibitor in a suitable amount. The Examples of the invention were evaluated as globally good (indicated by “O” in Tables).
[0327] (16) [Mixed Cable Bundle of PVC-Type Electrical Cables (with Anti-Oxidizing Agent) and HF-Type Electrical Cables]×HF-Type Adhesive Tape (with Copper Damage Inhibitor)
[0328] Table 26 shows the results of the tests carried out with a (mixed cable bundle of PVC-type electrical cables (with anti-oxidizing agent) and HF-type electrical cables)×HF-type adhesive tape (with copper damage inhibitor). As to the mandrel-winding test, cracks were found in the HF-type electrical cables in the wire harness (cable number ratio of 29:1, 20:10 and 1:29) of Prior Art W16, and the latter was evaluated as defective. It was understood that the adhesive-side deterioration accelerators and the tape base-side deterioration accelerators moved into the cable coatings of HF-type electrical cables, thereby causing the copper damage and decrease of anti-oxidizing agent in the cable coatings.
[0329] The HF-type adhesive tape itself of Prior Art 4 formed cracks, and considered to be failed. This cracking was caused by the migration of the adhesive-side deterioration accelerators into the tape base.
[0330] By comparison, the HF-type electrical cables in wire harnesses of Examples W76 to W80 did not form any crack by the mandrel-winding tests. In the above preparation, the HF-type adhesive tapes (with copper damage inhibitor) of Examples 16 to 20 were supplied with an adhesive adjuvant made of a low-reactivity specific resin hardly prone to bond with other atoms and molecules, so that the copper damage, due to the migration of adhesive adjuvant, was at least prevented. Further, the adhesive and tape base contained an anti-oxidizing agent in a suitable amount. Accordingly, when the copper damage inhibitor was consumed by the migration of the adhesive-side deterioration accelerators and tape base-side deterioration accelerators other than the adhesive adjuvant, a fresh copper damage inhibitor was supplied from the adhesive tape to the cable coatings. The copper damage could thus be securely avoided.
[0331] Moreover, in the present Examples, PVC-type electrical cables containing an anti-oxidizing agent were used. Accordingly, even if the plasticizers and the like contained in the cable coatings of PVC-type electrical cables moved into the cable coatings of HF-type electrical cables, the deterioration of the cable coatings of HF-type electrical cables, owing to the agent migration between the electrical cables, could be efficiently prevented.
[0332] As to the ease of wrapping operation, tape appearance and gluing capacity, the HF-type adhesive tape (with copper damage inhibitor) of Comparative Example 4 was judged as defective, the reason for this failure being probably that it contained an excess amount of copper damage inhibitor. By comparison, the HF-type adhesive tapes (with copper damage inhibitor) of Examples 16 to 20 were found good in ease of wrapping operation, tape appearance and gluing capacity, the reason for this being that they contained the copper damage inhibitor in a suitable amount. The Examples of the invention were evaluated as globally good (indicated by “O” in Tables).
[0333] (17) [Mixed Cable Bundle of PVC-Type Electrical Cables (with Anti-Oxidizing Agent) and HF-Type Electrical cables]×PVC-Type Adhesive Tape (with Anti-Oxidizing Agent and Copper Damage Inhibitor)
[0334] Table 27 shows the results of the tests carried out with a [mixed cable bundle of PVC-type electrical cables (with anti-oxidizing agent) and HF-type electrical cables]×PVC-type adhesive tape (with anti-oxidizing agent and copper damage inhibitor). As to the mandrel-winding test, cracks were found in the HF-type electrical cables in the wire harness (cable number ratio of 29:1, 20:10 and 1:29) of Prior Art W17, and the latter was evaluated as defective. It was understood that the adhesive-side deterioration accelerators and the tape base-side deterioration accelerators moved into the cable coatings of HF-type electrical cables, thereby causing the copper damage and decrease of anti-oxidizing agent in the cable coatings.
[0335] By comparison, the HF-type electrical cables in wire harnesses of Examples W81 to W85 did not form any crack by the mandrel-winding tests. The use of a specific resin as adhesive adjuvant in the adhesive, as well as the presence of anti-oxidizing agent and copper damage inhibitor in the adhesive and tape base in a suitable amount, produced a synergic effect. In this manner, the decrease of the anti-oxidizing agent in cable coatings and the copper damage due to copper ions could be prevented efficiently.
[0336] Moreover, in the present Examples, PVC-type electrical cables containing an anti-oxidizing agent were used. Accordingly, even if the plasticizers and the like contained in the cable coatings of PVC-type electrical cables moved into the cable coatings of HF-type electrical cables, the deterioration of the cable coatings of HF-type electrical cables, owing to the agent migration between the electrical cables, could be efficiently prevented.
[0337] As to the ease of wrapping operation, tape appearance and gluing capacity, the PVC-type adhesive tape (with anti-oxidizing agent and copper damage inhibitor) of Comparative Example 5 was judged as defective, the reason for this deficiency being probably that it contained an excess amount of copper damage inhibitor. By comparison, the PVC-type adhesive tapes (with anti-oxidizing agent and copper damage inhibitor) of Examples 21 to 25 were found good in ease of wrapping operation, tape appearance and gluing capacity, the reason for this being that they contained the anti-oxidizing agent and copper damage inhibitor in a suitable amount. The Examples of the invention were evaluated as globally good (indicated by “O” in Tables).
[0338] (18) [Mixed Cable Bundle of PVC-Type Electrical Cables (with Anti-Oxidizing Agent) and HF-Type Electrical Cables]×HF-Type Adhesive Tape (with Anti-Oxidizing Agent and Copper Damage Inhibitor)
[0339] Table 28 shows the results of the tests carried out with a [mixed cable bundle of PVC-type electrical cables (with anti-oxidizing agent) and HF-type electrical cables]×HF-type adhesive tape (with anti-oxidizing agent and copper damage inhibitor). As to the mandrel-winding test, cracks were found in the HF-type electrical cables in the wire harness (cable number ratio of 29:1, 20:10 and 1:29) of Prior Art W18, and the latter was evaluated as defective. It was understood that the adhesive-side deterioration accelerators and the tape base-side deterioration accelerators moved into the cable coatings of HF-type electrical cables, thereby causing the copper damage and decrease of anti-oxidizing agent in the cable coatings.
[0340] The HF-type adhesive tape itself of Prior Art 6 formed cracks, and considered to be failed. This cracking was caused by the migration of the adhesive-side deterioration accelerators into the tape base.
[0341] By comparison, the HF-type electrical cables in wire harnesses of Examples W26 to W30 did not form any crack by the mandrel-winding tests. The use of a specific resin as adhesive adjuvant in the adhesive, as well as the presence of anti-oxidizing agent and copper damage inhibitor in the adhesive and tape base in a suitable amount, produced a synergic effect. In this manner, the decrease of the anti-oxidizing agent in cable coatings and the copper damage due to copper ions could be prevented efficiently.
[0342] Moreover, in the present Examples, PVC-type electrical cables containing an anti-oxidizing agent were used. Accordingly, even if the plasticizers and the like contained in the cable coatings of PVC-type electrical cables moved into the cable coatings of HF-type electrical cables, the deterioration of the cable coatings of HF-type electrical cables, owing to the agent migration between the electrical cables, could be efficiently prevented.
[0343] As to the ease of wrapping operation, tape appearance and gluing capacity, the HF-type adhesive tape (with anti-oxidizing agent and copper damage inhibitor) of Comparative Example 6 was judged as defective, the reason for this failure being probably that it contained an excess amount of copper damage inhibitor. By comparison, the HF-type adhesive tapes (with anti-oxidizing agent and copper damage inhibitor) of Examples 26 to 30 were found good in ease of wrapping operation, tape appearance and gluing capacity, the reason for this being that they contained the anti-oxidizing agent and copper damage inhibitor in a suitable amount. The Examples of the invention were evaluated as globally good (indicated by “O” in Tables).
[0344] The above embodiment was explained using a particular adhesive adjuvant made of specific resin, an anti-oxidizing agent, a copper damage inhibitor and/or a filler. However, the invention is not limited to the above particular compounds, and other additives may also be used.
[0345] In the above embodiment, a cable bundle containing PVC-type electrical cables only (PVC-type plain bundle) and the wire harness comprising this cable bundle were not specifically mentioned. However, the invention can also be applied to such cable bundle and wire harness.
[0346] According to the harness-protecting material of the invention, at least the copper damage, caused by the migration of the adhesive adjuvant, is prevented. Further, the copper damage caused by the migration of the adhesive-side and the tape base-side deterioration accelerators, as well as the decrease of the anti-oxidizing agent in the cable coatings, are efficiently prevented. As a result, when a wire harness comprises such a harness-protecting material e.g. in the form of a tape, the electrical cables contained in the cable bundles of wire harness, in particular, those coated with a HF-type resin, are protected from rapid degradation. Such a wire harness can produce a durable good quality.
[0347] When such a wire harness is used in severe environments, e.g. near the automobile motors, it shows a remarkable reliability, creating thus a great industrial advantage.
[0348] Embodiment 2
[0349] The compositions of the cable coatings for HF-type electrical cables and PVC-type electrical cables (Tables 1, 2 and 3), and the preparation methods for coated electrical cables, mentioned for Embodiment 1, are applied mutatis mutandis to Embodiment 2.
[0350] Adhesive Tape as a Harness-Protecting Material
[0351] The adhesive tape as harness-protecting material of the invention is explained hereunder. Six types of adhesive tape were prepared. The tape base and the adhesive have a thickness of, respectively, 0.11 mm and 0.02 mm.
[0352] Table 29 shows the composition of a first type of adhesive tape. The first type comprises a PVC-type anti-oxidizing adhesive tape (Examples 1 to 6), in which the tape base was formed of a vinyl chloride resin containing an anti-oxidizing agent, one face of which was painted with an adhesive that contained an adhesive adjuvant made of a specific resin, and an anti-oxidizing agent.
[0353] The tape base comprised 60 parts by weight of di-octylphthalate (DOP) as plasticizer, 20 parts by weight of calcium carbonate as fillers, 5 parts by weight of stabilizer, 5 parts by weight of anti-oxidizing agent and, respectively, 1, 10 and 150 parts by weight of carbon black (Examples 1 to 3) or silica (Examples 4 to 6) as adsorbent, relative to 100 parts by weight of polyvinyl chloride (PVC; polymerisation degree: 1300). For the purpose of the invention, PVC in the above case was defined as “base polymer portion” of the tape base, and PVC and DOP as “base organic material portion” of the tape base, the both portions excluding the organic compounds used for anti-oxidizing agents and/or copper damage inhibitors.
[0354] The adhesive of Examples 1 to 6 comprised 70 parts by weight of styrene butadiene rubber, 30 parts by weight of natural rubber and 20 parts by weight of zinc white. The adhesive adjuvant made of a specific resin comprised 80 parts by weight of hydrogenated aromatic resin, 6 parts by weight of anti-oxidizing agent and, respectively, 1, 10 and 150 parts by weight of carbon black (Examples 1 to 3) or of silica (Examples 4 to 6) as adsorbent. In the above case, the base polymer portion of the adhesive was composed of styrene butadiene rubber and natural rubber, and the base organic material portion of the adhesive is composed of styrene butadiene rubber, natural rubber and hydrogenated aromatic resin.
[0355] In comparison with Examples 1 to 6, Table 29 comprises Comparative Example 1 in which carbon black was added in a proportion of 160 parts by weight, and Comparative Example 2 in which silica was added in a proportion of 160 parts by weight. Table 29 further comprises Prior Art 1, in which the tape base and adhesive contained no adsorbent and no anti-oxidizing agent, but contained, as adhesive adjuvant, a rosin-type resin instead of the foregoing specific resin.
[0356] A second type of the adhesive tape comprised a HF-type anti-oxidizing adhesive tape (Examples 7 to 12), in which the tape base was formed of a HF-type resin containing an adsorbent and an anti-oxidizing agent, one face of which was painted with an adhesive that contained an adhesive adjuvant made of a specific resin, and an adsorbent and an anti-oxidizing agent. Table 30 shows the composition of the HF-type adhesive tapes of Examples 7 to 12.
[0357] The tape base comprised 3 parts by weight of bromine-type flame-retardant, 1.5 parts by weight of antimony trioxide, 3.5 parts by weight of anti-oxidizing agent and, respectively, 1, 10 and 150 parts by weight of carbon black (Examples 7 to 9) or silica (Examples 10 to 12) as adsorbent, relative to 100 parts by weight of polyolefin. In the above case, the base polymer portion of the tape base is composed of polyolefin, and the base organic material portion of the tape base was composed of polyolefin and bromine-type retardant.
[0358] The adhesive of Examples 7 to 12 comprised 70 parts by weight of styrene butadiene rubber, 30 parts by weight of natural rubber and 20 parts by weight of zinc white. The adhesive adjuvant made of a specific resin comprised 80 parts by weight of hydrogenated aromatic resin, 6 parts by weight of anti-oxidizing agent and, respectively, 1, 10 and 150 parts by weight of carbon black (Examples 7 to 9) or of silica (Examples 10 to 12) as adsorbent.
[0359] In comparison with Examples 7 to 12, Table 30 also comprised a Comparative Example 3, in which carbon black was added in a proportion of 160 parts by weight, and Comparative Example 4 in which silica was added in a proportion of 160 parts by weight. Table 30 further comprises Prior Art 2, in which the tape base and adhesive contained no adsorbent and no anti-oxidizing agent, but contained, as adhesive adjuvant, a rosin-type resin instead of the foregoing specific resin.
[0360] A third type of the adhesive tape comprised a PVC-type copper damage-preventing adhesive tape (Examples 13 to 18), in which the tape base was formed of a vinyl chloride resin containing an adsorbent and a copper damage inhibitor, one face of which was painted with an adhesive that contained an adhesive adjuvant made of a specific resin, and an adsorbent and a copper damage inhibitor. Table 31 shows the composition of the PVC-type copper damage-preventing adhesive tapes of Examples 13 to 18.
[0361] The tape base comprised 60 parts by weight of DOP as plasticizer, 20 parts by weight of calcium carbonate as fillers, 5 parts by weight of stabilizer, 1.6 parts by weight of copper damage inhibitor and, respectively, 1, 10 and 150 parts by weight of carbon black (Examples 13 to 15) or of silica (Examples 16 to 18) as adsorbent, relative to 100 parts by weight of PVC (P: 1300).
[0362] The adhesive of Examples 13 to 18 comprised 70 parts by weight of styrene butadiene rubber, 30 parts by weight of natural rubber and 20 parts by weight of zinc white. Examples 13 to 18 further comprised, as adhesive adjuvant made of a specific resin, 80 parts by weight of hydrogenated aromatic resin, 1.8 parts by weight of copper damage inhibitor and, respectively, 1, 10 and 150 parts by weight of carbon black (Examples 13 to 15) or of silica (Examples 16 to 18).
[0363] Table 31 also comprises a Comparative Example 5 in which carbon black was added in a proportion of 160 parts by weight, and Comparative Example 6 in which silica was added in a proportion of 160 parts by weight. Table 31 further comprises Prior Art 3, in which the tape base and adhesive contained no adsorbent and no copper damage inhibitor, but contained, as adhesive adjuvant, a rosin-type resin instead of the foregoing specific resin.
[0364] A fourth type of the adhesive tape comprised a HF-type copper damage-preventing adhesive tape (Examples 19 to 24), in which the tape base was formed of a HF-type resin containing an adsorbent and a copper damage inhibitor, one face of which was painted with an adhesive that contained an adhesive adjuvant made of a specific resin, and an adsorbent and a copper damage inhibitor. Table 32 shows the composition of the HF-type copper damage-preventing adhesive tapes of Examples 19 to 24.
[0365] The tape base comprised 3 parts by weight of bromine-type flame-retardant, 1.5 parts by weight of antimony trioxide, 1 part by weight of copper damage inhibitor and, respectively, 1, 10 and 150 parts by weight of carbon black (Examples 19 to 21) or of silica (Examples 22 to 24) as adsorbent, relative to 100 parts by weight of polyolefin.
[0366] The adhesive of Examples 19 to 24 comprised 70 parts by weight of styrene butadiene rubber, 30 parts by weight of natural rubber and 20 parts by weight of zinc white. Examples 19 to 24 further comprised, as adhesive adjuvant made of a specific resin, 80 parts by weight of hydrogenated aromatic resin, 1.8 parts by weight of copper damage inhibitor and, respectively, 1, 10 and 150 parts by weight of carbon black (Examples 19 to 21) or of silica (Examples 22 to 24).
[0367] Table 32 also comprises a Comparative Example 7 in which carbon black was added in a proportion of 160 parts by weight, and Comparative Example 8 in which silica was added in a proportion of 160 parts by weight. Table 32 further comprises Prior Art 4, in which the tape base and adhesive contained no adsorbent and no copper damage inhibitor, but contained, as adhesive adjuvant, a rosin-type resin instead of the foregoing specific resin.
[0368] A fifth type of the adhesive tape comprised a PVC-type, anti-oxidizing and copper damage inhibiting adhesive tape (Examples 25 to 30), in which the tape base was formed of a vinyl chloride resin containing an adsorbent, an anti-oxidizing agent and a copper damage inhibitor, one face of which was painted with an adhesive that contained an adhesive adjuvant made of a specific resin, and an adsorbent, an anti-oxidizing agent and a copper damage inhibitor. Table 33 shows the composition of the PVC-type, anti-oxidizing and copper damage-inhibiting adhesive tapes of Examples 25 to 30.
[0369] The tape base comprised 60 parts by weight of DOP as plasticizer, 20 parts by weight of calcium carbonate as fillers, 5 parts by weight of stabilizer, 5 parts by weight of anti-oxidizing agent, 1.6 parts by weight of copper damage inhibitor and, respectively 1, 10 and 150 parts by weight of carbon black (Examples 25 to 27) or of silica (Examples 28 to 30) as adsorbent, relative to 100 parts by weight of PVC (P: 1300).
[0370] The adhesive of Examples 25 to 30 comprised 70 parts by weight of styrene butadiene rubber, 30 parts by weight of natural rubber and 20 parts by weight of zinc white. Examples 25 to 30 further comprised, as adhesive adjuvant made of a specific resin, 80 parts by weight of hydrogenated aromatic resin, 6 parts by weight of anti-oxidizing agent and, respectively, 1, 10 and 150 parts by weight of carbon black (Examples 25 to 27) or of silica (Examples 28 to 30) as adsorbent.
[0371] Table 33 also comprises a Comparative Example 9 in which carbon black was added in a proportion of 160 parts by weight, and Comparative Example 10 in which silica was added in a proportion of 160 parts by weight. Table 33 further comprises Prior Art 5, in which the tape base and adhesive contained no adsorbent, no anti-oxidizing agent and no copper damage inhibitor, but contained, as adhesive adjuvant, a rosin-type resin instead of the foregoing specific resin.
[0372] A sixth type of the adhesive tape comprised a HF-type, anti-oxidizing and copper damage-inhibiting adhesive tape (Examples 31 to 36), in which the tape base was formed of a HF-type resin containing an adsorbent, an anti-oxidizing agent and a copper damage inhibitor, one face of which was painted with an adhesive that contained an adhesive adjuvant made of a specific resin, and an adsorbent, an anti-oxidizing agent and a copper damage inhibitor. Table 34 shows the composition of the HF-type, anti-oxidizing and copper damage-inhibiting adhesive tapes of Examples 31 to 36.
[0373] The tape base comprised 3 parts by weight of bromine-type flame-retardant, 1.5 parts by weight of antimony trioxide, 3.5 parts by weight of anti-oxidizing agent, 1 part by weight of copper damage inhibitor and, respectively, 1, 10, and 150 parts by weight of carbon black (Examples 31 to 33) or of silica (Examples 34 to 36), relative to 100 parts by weight of polyolefin.
[0374] The adhesive of Examples 31 to 36 comprised 70 parts by weight of styrene butadiene rubber, 30 parts by weight of natural rubber and 20 parts by weight of zinc white. Examples 31 to 36 further comprised, as adhesive adjuvant made of a specific resin, 80 parts by weight of hydrogenated aromatic resin, 6 parts by weight of anti-oxidizing agent, 1.8 parts by weight of copper damage inhibitor, and, respectively, 1, 10 and 150 parts by weight of carbon black (Examples 31 to 33) or of silica (Examples 34 to 36) as adsorbent.
[0375] Table 34 also comprises a Comparative Example 11, in which carbon black was added in a proportion of 160 parts by weight, and Comparative Example 12 in which silica was added in a proportion of 160 parts by weight. Table 34 further comprises Prior Art 6, in which the tape base and adhesive contained no adsorbent, no anti-oxidizing agent and no copper damage inhibitor, but contained, as adhesive adjuvant, a rosin-type resin instead of the foregoing specific resin.
[0376] Table 4 shows the cable coatings and harness-protecting materials (adhesive tapes) used in the present invention, as well as manufactures of those products. Carbon black and silica have a specific surface of respectively 42 n 2 /g and 210 m 2 /g.
[0377] Cable Bundles
[0378] The cable bundle, around which the adhesive tape as harness-protecting material was wrapped, comprised three types.
[0379] A first type relates to a HF-type plain electrical cable, in which 30 HF-type electrical cables were assembled into a cable bundle, and the latter was wrapped with the cable coatings referred to in Table 1.
[0380] A second type relates to a PVC- and HF-type mixed cable bundle, in which there were provided electrical cables wrapped with the cable coatings referred to in Table 1 and those wrapped with the cable coatings referred to in Table 2, and they were assembled in a given mixture ratio, i.e. PVC:HF (by number of cables)=29:1; 20:10 and 1:29.
[0381] A third type relates to a mixed cable bundle of PVC-type anti-oxidizing electrical cables and HF-type electrical cables, in which PVC-type electrical cables covered with the cable coatings (containing an anti-oxidizing agent) referred to in Table 3, and HF-type electrical cables covered with the cable coatings referred to in Table 1 were mixed in a given ratio. The ratio of PVC-type anti-oxidizing electrical cables to HF-type electrical cables (by number of cables) was: 29:1, 20:10 and 1/29.
[0382] When, in the second and third types, only one electrical cable was different from the others, that electrical cable was assembled such that it was placed in contact with the adhesive of the adhesive tape. When the ratio was 20:10, the electrical cables of one type were assembled such that they were well mingled with the electrical cables of another type.
[0383] Wire Harness
[0384] A wire harness was prepared by wrapping the electrical cables with the adhesive tape as a harness-protecting material of the invention. As 6 types of adhesive tape and 3 types of cable bundle were prepared, the wire harnesses produced included 18 sorts of combinations.
[0385] First, the HF-type plain cable bundles were wrapped with PVC-type adhesive tapes (with anti-oxidizing agent) of Examples 1 to 6, to prepare wire harnesses W1 to W6. Second, the HF-type plain cable bundles were wrapped with HF-type adhesive tapes (with anti-oxidizing agent) of Examples 7 to 12, to prepare wire harnesses W7 to W12. Third, the HF-type plain cable bundles were wrapped with PVC-type adhesive tapes (with copper damage inhibitor) of Examples 13 to 18, to prepare wire harnesses W13 to W18. Fourth, the HF-type plain cable bundles were wrapped with HF-type adhesive tapes (with copper damage inhibitor) of Examples 19 to 24, to prepare wire harnesses W19 to W24. Fifth, the HF-type plain cable bundles were wrapped with PVC-type adhesive tapes (with anti-oxidizing agent and copper damage inhibitor) of Examples 25 to 30, to prepare wire harnesses W25 to W30. Sixth, the HF-type plain cable bundles were wrapped with HF-type adhesive tapes (with anti-oxidizing agent and copper damage inhibitor) of Examples 31 to 36, to prepare wire harnesses W31 to W36. Further, the adhesive tapes of Comparative Examples 1 to 12 and of Prior Art 1 to 6 were wrapped around the HF-type plain cable bundles, to prepare the corresponding wire harnesses.
[0386] Likewise, firstly, the mixed cable bundles comprising PVC-type electrical cables and HF-type electrical cables were wrapped with PVC-type adhesive tapes (with anti-oxidizing agent) of Examples 1 to 6, to prepare wire harnesses W37 to W42. Second, the corresponding mixed cable bundles were wrapped with HF-type adhesive tapes (with anti-oxidizing agent) of Examples 7 to 12, to prepare wire harnesses W43 to W48. Third, the corresponding mixed cable bundles were wrapped with PVC-type adhesive tapes (with copper damage inhibitor) of Examples 13 to 18, to prepare wire harnesses W49 to W54. Fourth, the corresponding mixed cable bundles were wrapped with HF-type adhesive tapes (with copper damage inhibitor) of Examples 19 to 24, to prepare wire harnesses W55 to W60. Fifth, the corresponding mixed cable bundles were wrapped with PVC-type adhesive tapes (with anti-oxidizing agent and copper damage inhibitor) of Examples 25 to 30, to prepare wire harnesses W61 to W66. Sixth, the corresponding mixed cable bundles were wrapped with HF-type adhesive tapes (with anti-oxidizing agent and copper damage inhibitor) of Examples 31 to 36, to prepare wire harnesses W67 to W72. Further, the adhesive tapes of Comparative Examples 1 to 12 and of Prior Art 1 to 6 were wrapped around the mixed cable bundles, to prepare the corresponding wire harnesses.
[0387] Further, firstly, the mixed cable bundles comprising PVC-type electrical cables (with anti-oxidizing agent) and HF-type electrical cables were wrapped with PVC-type adhesive tapes (with anti-oxidizing agent) of Examples 1 to 6, to prepare wire harnesses W73 to W78. Second, the corresponding mixed cable bundles were wrapped with HF-type adhesive tapes (with anti-oxidizing agent) of Examples 7 to 12, to prepare wire harnesses W79 to W84. Third, the corresponding mixed cable bundles were wrapped with PVC-type adhesive tapes (with copper damage inhibitor) of Examples 13 to 18, to prepare wire harnesses W85 to W90. Fourth, the corresponding mixed cable bundles were wrapped with HF-type adhesive tapes (with copper damage inhibitor) of Examples 19 to 24, to prepare wire harnesses W91 to W96. Fifth, the corresponding mixed cable bundles were wrapped with PVC-type adhesive tapes (with anti-oxidizing agent and copper damage inhibitor) of Examples 25 to 30, to prepare wire harnesses W97 to W102. Sixth, the corresponding mixed cable bundles were wrapped with HF-type adhesive tapes (with anti-oxidizing agent and copper damage inhibitor) of Examples 31 to 36, to prepare wire harnesses W103 to W108. Further, the adhesive tapes of Comparative Examples 1 to 12 and of Prior Art 1 to 6 were wrapped around the mixed cable bundles, to prepare the corresponding wire harnesses.
[0388] Test Methods
[0389] The wire harnesses thus prepared were subjected to various tests as follows. Each wire harness was allowed to stand in a thermostat at 150° C. for 96 hours. The wire harness was then withdrawn from the thermostat and the adhesive tape was stripped off the wire harness. The electrical cables in each cable bundle were wound around a mandrel of φ 10 mm, and visually observed whether cracks were formed in the cable coatings. Likewise, when preparing wire harness, the adhesive tape was wrapped around the cable bundle and the ease of wrapping operation was evaluated. Further, when preparing the adhesive tape, the gluing capacity of the adhesive was evaluated. When the copper damage inhibitor was added to the adhesive tape, the appearance of the tape was also observed.
[0390] Test Results
[0391] (1) HF-Type Plain Cable Bundle×PVC-Type Adhesive Tape (with Anti-Oxidizing Agent)
[0392] The HF-type plain cable bundle was wrapped with a PVC-type adhesive tape (with anti-oxidizing agent) to form a wire harness, which was indicated as “HF-type plain cable bundle×PVC-type adhesive tape (with anti-oxidizing agent)”. The other wire harnesses were also indicated in the same manner, unless otherwise mentioned.
[0393] Table 35 shows the results of the tests carried out with a HF-type plain cable bundle×PVC-type adhesive tape (with anti-oxidizing agent). As to the mandrel-winding test, cracks were found in the HF-type electrical cables in Prior Art W1 (wire harness), and the latter were evaluated as defective. It was understood that the adhesive-side deterioration accelerators and the tape base-side deterioration accelerators moved into the cable coatings of HF-type electrical cables, thereby causing the copper damage and decrease in anti-oxidizing agent in the cable coatings.
[0394] By comparison, the HF-type electrical cables in wire harnesses of Examples W1 to W6 did not form any crack by the mandrel-winding tests. In the PVC-type adhesive tapes (with anti-oxidizing agent) of Examples 1 to 6, the adhesive and tape base contained an adsorbent, so that the latter adsorbed the adhesive-side deterioration accelerators and tape base-side deterioration accelerators and prevented them from moving into the cable coatings. The presence of anti-oxidizing agent in the adhesive and tape base also produced a great effect.
[0395] As to the ease of wrapping operation and gluing capacity, the PVC-type adhesive tapes (with anti-oxidizing agent) of Comparative Examples 1 and 2 were judged as defective, the reason for this deficiency being probably that they contained an excess quantity of adsorbent. By comparison, the PVC-type adhesive tapes (with anti-oxidizing agent) of Examples 1 to 6 were found good in ease of wrapping operation and gluing capacity, the reason for this being probably that they contained the adsorbent in a suitable amount. The Examples of the invention were evaluated as globally good (indicated by “O” in Tables)
[0396] (2) HF-Type Plain Cable Bundle×HF-Type Adhesive Tape (with Anti-Oxidizing Agent).
[0397] Table 36 shows the results of the tests effected with the HF-type plain cable bundle×HF-type adhesive tape (with anti-oxidizing agent). According to the mandrel-winding tests, the HF-type electrical cables in the wire harness of Prior Art W2 formed cracks and were found defective. It is probably because the adhesive-side deterioration accelerators and tape base-side deterioration accelerators moved into the cable coatings of HF-type electrical cables, thereby causing the copper damage and decrease in anti-oxidizing agent in the cable coatings.
[0398] The HF-type adhesive tape itself of Prior Art 2 formed cracks probably because the adhesive-side deterioration accelerators moved into the tape base. This adhesive tape was thus found defective.
[0399] The HF-type electrical cables in the wire harnesses of Examples W7 to W12 formed no crack by the mandrel-winding tests. In the HF-type adhesive tapes (with anti-oxidizing agent) of Examples 7 to 12, the adhesive and tape base contained an adsorbent, which adsorbed the adhesive-side deterioration accelerators and tape base-side deterioration accelerators and prevented them from moving into the cable coatings. The presence of anti-oxidizing agent in the adhesive and tape base also produced a great effect.
[0400] As to the ease of wrapping operation and gluing capacity, HF-type adhesive tapes (with anti-oxidizing agent) of Comparative Examples 3 and 4 were judged as defective, the reason for this being probably that they contained an excess of adsorbent. By comparison, the HF-type adhesive tapes (with anti-oxidizing agent) of Examples 7 to 12 were found good in ease of wrapping operation and gluing capacity, the reason for this being probably that they contained the adsorbent in a suitable amount. The Examples of the invention were evaluated as globally good (“0”).
[0401] (3) HF-Type Plain Cable Bundle×PVC-Type Adhesive Tape (with Copper Damage Inhibitor)
[0402] Table 37 shows the results of the tests effected with the HF-type plain cable bundle×PVC-type adhesive tape (with copper damage inhibitor). According to the mandrel-winding tests, the HF-type electrical cables in the wire harness of Prior Art W3 formed cracks and were found defective. It is probably because the adhesive-side deterioration accelerators and tape base-side deterioration accelerators moved into the cable coatings of HF-type electrical cables, thereby causing the copper damage and decrease in anti-oxidizing agent in the cable coatings.
[0403] The HF-type electrical cables in the wire harnesses of Examples W13 to W18 formed no crack by the mandrel-winding tests. In the PVC-type adhesive tapes (with copper damage inhibitor) of Examples 13 to 18, the adhesive and tape base contained an adsorbent, which adsorbed the adhesive-side deterioration accelerators and tape base-side deterioration accelerators and prevented them from moving into the cable coatings. The presence of copper damage inhibitor in the adhesive and tape base also produced a great effect.
[0404] As to the ease of wrapping operation and gluing capacity, the PVC-type adhesive tapes (with copper damage inhibitor) of Comparative Examples 5 and 6 were judged as defective, the reason for this being probably that they contained an excess of adsorbent. By comparison, the PVC-type adhesive tapes (with copper damage inhibitor) of Examples 13 to 18 were found good in ease of wrapping operation and gluing capacity, the reason for this being probably that they contained the adsorbent in a suitable amount. There was no particular problem for tape appearance. The Examples of the invention were evaluated as globally good (“O”).
[0405] (4) HF-Type Plain Cable Bundle×HF-Type Adhesive Tape (with Copper Damage Inhibitor)
[0406] Table 38 shows the results of the tests effected with the HF-type plain cable bundle×HF-type adhesive tape (with copper damage inhibitor). According to the mandrel-winding tests, the HF-type electrical cables in the wire harness of Prior Art W4 formed cracks and were found defective. It is probably because the adhesive-side deterioration accelerators and tape base-side deterioration accelerators moved into the cable coatings of HF-type electrical cables, thereby causing the copper damage and decrease in anti-oxidizing agent in the cable coatings.
[0407] The HF-type adhesive tape itself of Prior Art 4 formed cracks probably because the adhesive-side deterioration accelerators moved into the tape base. The adhesive tape was thus found defective.
[0408] The HF-type electrical cables in the wire harnesses of Examples W19 to W24 formed no crack by the mandrel-winding tests. In the HF-type adhesive tapes (with copper damage inhibitor) of Examples 19 to 24, the adhesive and tape base contained an adsorbent, which adsorbed the adhesive-side deterioration accelerators and tape base-side deterioration accelerators and prevented them from moving into the cable coatings. The presence of copper damage inhibitor in the adhesive and tape base also produced an important effect.
[0409] As to the ease of wrapping operation and gluing capacity, the HF-type adhesive tapes (with copper damage inhibitor) of Comparative Examples 7 and 8 were judged as defective, the reason for this being probably that they contained an excess of adsorbent. By comparison, the HF-type adhesive tapes (with copper damage inhibitor) of Examples 19 to 24 were found good in ease of wrapping operation and gluing capacity, the reason for this being probably that they contained the adsorbent in a suitable amount. There was no particular problem of tape appearance. The Examples of the invention were evaluated as globally good (“O”).
[0410] (5) HF-Type Plain Cable Bundle×PVC-Type Adhesive Tape (with Anti-Oxidizing Agent and Copper Damage Inhibitor)
[0411] Table 39 shows the results of the tests effected with the HF-type plain cable bundle×PVC-type adhesive tape (with anti-oxidizing agent and copper damage inhibitor). According to the mandrel-winding tests, the HF-type electrical cables in the wire harness of Prior Art W5 formed cracks and were found defective. It is probably because the adhesive-side deterioration accelerators and tape base-side deterioration accelerators moved into the cable coatings of HF-type electrical cables, thereby causing the copper damage and decrease in anti-oxidizing agent of the cable coatings.
[0412] The HF-type electrical cables in the wire harnesses of Examples W25 to W30 formed no crack by the mandrel-winding tests. The presence of adsorbent in the adhesive and tape base, the use of a specific resin as adhesive adjuvant in the adhesive and the presence of anti-oxidizing agent and copper damage inhibitor in the adhesive and tape base produced a synergic effect.
[0413] As to the ease of wrapping operation and gluing capacity, the PVC-type adhesive tapes (with anti-oxidizing agent and copper damage inhibitor) of Comparative Examples 9 and 10 were judged as defective, the reason for this being probably that they contained an excess of adsorbent. By comparison, the PVC-type adhesive tapes (with anti-oxidizing agent and copper damage inhibitor) of Examples 25 to 30 were found good in ease of wrapping operation and gluing capacity, the reason for this being that they contained the adsorbent in a suitable amount. There was no particular problem for tape appearance. The Examples of the invention were evaluated as globally good (“O”).
[0414] (6) HF-Type Plain Cable Bundle×HF-Type Adhesive Tape (with Anti-Oxidizing Agent and Copper Damage Inhibitor)
[0415] Table 40 shows the results of the tests effected with the HF-type plain cable bundle×HF-type adhesive tape (with anti-oxidizing agent and copper damage inhibitor). According to the mandrel-winding tests, the HF-type electrical cables in the wire harness of Prior Art W6 formed cracks and were found defective. It is because the adhesive-side deterioration accelerators and tape base-side deterioration accelerators moved into the cable coatings of HF-type electrical cables, thereby causing the copper damage and decrease in anti-oxidizing agent in the cable coatings.
[0416] The HF-type adhesive tape itself of Prior Art 6 formed cracks, because the adhesive-side deterioration accelerators moved into the tape base.
[0417] The HF-type electrical cables in the wire harnesses of Examples W31 to W36 formed no crack by the mandrel-winding tests. The presence of adsorbent in the adhesive and tape base, the use of a specific resin as adhesive adjuvant in the adhesive, as well as the presence of anti-oxidizing agent and copper damage inhibitor in the adhesive and tape base, apparently produced a synergic effect.
[0418] As to the ease of wrapping operation and gluing capacity, the HF-type adhesive tapes (with anti-oxidizing agent and copper damage inhibitor) of Comparative Examples 11 and 12 were judged as defective, the reason therefor being that they contained an excessive quantity of adsorbent. By comparison, the HF-type adhesive tapes (with anti-oxidizing agent and copper damage inhibitor) of Examples 31 to 36 were found good in ease of wrapping operation and gluing capacity, the reason for this being that they contained the adsorbent in a suitable amount. There was no particular problem for tape appearance The Examples of the invention were evaluated as globally good (“O”).
[0419] (7) (Mixed Cable Bundle of PVC-Type Electrical Cables and HF-Type Electrical Cables)×PVC-Type Adhesive Tape (with Anti-Oxidizing Agent)
[0420] Table 41 shows the results of the tests carried out with a (mixed cable bundle of PVC-type electrical cables and HF-type electrical cables)×PVC-type adhesive tape (with anti-oxidizing agent). As to the mandrel-winding test, cracks were found in the HF-type electrical cables in the wire harness (cable number ratio of 29:1, 20:10 and 1:29) of Prior Art W7, and the latter was evaluated as defective. It was understood that the adhesive-side deterioration accelerators and the tape base-side deterioration accelerators moved into the cable coatings of HF-type electrical cables, thereby causing the copper damage and decrease of anti-oxidizing agent in the cable coatings.
[0421] In particular, when the cable number ratio of PVC-type electrical cables and HF-type electrical cables was 29:1, the deterioration of the HF-type electrical cable tended to be very drastic. This may be caused by the fact that the plasticizer and the like contained in the cable coatings of PVC-type electrical cables moved into the coatings of HF-type electrical cables.
[0422] By comparison, the HF-type electrical cables in wire harnesses of Examples W37 to W42 did not form any crack by the mandrel-winding tests. In the PVC-type adhesive tapes (with anti-oxidizing agent) of Examples 1 to 6, the adhesive and tape base contain an adsorbent, which adsorbed the adhesive-side deterioration accelerators and tape base-side deterioration accelerators and prevented them from moving into the cable coatings. The presence of anti-oxidizing agent in the adhesive and tape base also produced a great effect.
[0423] However, in this case also, the plasticizers and the like contained in the cable coatings of PVC-type electrical cables may move into the cable coatings of HF-type electrical cables, thereby causing the deterioration of the HF-type electrical cables due to the agent migration between the electrical cables. The fact that this did not happen in the Examples of the invention indicates that the anti-oxidizing agent in the PVC-type adhesive tape moves into the cable coatings of HF-type electrical cables, thereby supplying the anti-oxidizing agent to the cable coatings.
[0424] As to the ease of wrapping operation and gluing capacity, the PVC-type adhesive tapes (with anti-oxidizing agent) of Comparative Examples 1 and 2 were judged as defective, the reason for this deficiency being probably that they contained an excess amount of adsorbent. By comparison, the PVC-type adhesive tapes (with anti-oxidizing agent) of Examples 1 to 6 were found good in ease of wrapping operation and gluing capacity, the reason for this being that they contained the adsorbent in a suitable amount. The Examples of the invention were evaluated as globally good (indicated by “O” in Tables)
[0425] (8) (Mixed Cable Bundle of PVC-Type Electrical Cables and HF-Type Electrical Cables)×HF-Type Adhesive Tape (with Anti-Oxidizing Agent)
[0426] Table 42 shows the results of the tests carried out with a (mixed cable bundle of PVC-type electrical cables and HF-type electrical cables)×HF-type adhesive tape (with anti-oxidizing agent). As to the mandrel-winding test, cracks were found in the HF-type electrical cables in the wire harness (cable number ratio of 29:1, 20:10 and 1:29) of Prior Art W8, and the latter was evaluated as defective. It was understood that the adhesive-side deterioration accelerators and the tape base-side deterioration accelerators moved into the cable coatings of HF-type electrical cables, thereby causing the copper damage and decrease of anti-oxidizing agent in the cable coatings.
[0427] In particular, when the cable number ratio of PVC-type electrical cables and HF-type electrical cables was 29:1, the deterioration of the HF-type electrical cable tended to be very strong. This may be caused by the fact that the plasticizer and the like contained in the cable coatings of PVC-type electrical cables moved into the coatings of HF-type electrical cables.
[0428] Further, the HF-type adhesive tape itself of Prior Art 2 formed cracks, and was judged defective. This cracking was caused by the fact that the adhesive-side deterioration accelerators moved into the tape base.
[0429] By comparison, the HF-type electrical cables in wire harnesses of Examples W43 to W48 did not form any crack by the mandrel-winding tests. In the HF-type adhesive tapes (with anti-oxidizing agent) of Examples 7 to 12, the adhesive and tape base contained an adsorbent, which adsorbed the adhesive-side deterioration accelerators and tape base-side deterioration accelerators and prevented them from moving into the cable coatings. The presence of anti-oxidizing agent in the adhesive and tape base also produced a great effect.
[0430] However, in this case also, the plasticizers and the like contained in the cable coatings of PVC-type electrical cables may move into the cable coatings of HF-type electrical cables, thereby causing the deterioration of the HF-type electrical cables due to the agent migration between the electrical cables. The fact that this did not happen in the Examples of the invention indicates that the anti-oxidizing agent in the HF-type adhesive tape moved into the cable coatings of HF-type electrical cables, thereby supplying the anti-oxidizing agent to the cable coatings.
[0431] As to the ease of wrapping operation and gluing capacity, the HF-type adhesive tapes (with anti-oxidizing agent) of Comparative Examples 3 and 4 were judged as defective, the reason for this deficiency being probably that they contained an excess amount of adsorbent. By comparison, the HF-type adhesive tapes (with anti-oxidizing agent) of Examples 7 to 12 were found good in ease of wrapping operation and gluing capacity, the reason for this being that they contained the adsorbent in a suitable amount. The Examples of the invention were evaluated as globally good (indicated by “O” in Tables)
[0432] (9) (Mixed Cable Bundle of PVC-Type Electrical Cables and HF-Type Electrical Cables)×PVC-Type Adhesive Tape (with Copper Damage Inhibitor)
[0433] Table 43 shows the results of the tests carried out with a (mixed cable bundle of PVC-type electrical cables and HF-type electrical cables)×PVC-type adhesive tape (with copper damage inhibitor). As to the mandrel-winding test, cracks were found in the HF-type electrical cables in the wire harness (cable number ratio of 29:1, 20:10 and 1:29) of Prior Art W9, and the latter was evaluated as defective. It was understood that the adhesive-side deterioration accelerators and the tape base-side deterioration accelerators moved into the cable coatings of HF-type electrical cables, thereby causing the copper damage and decrease of anti-oxidizing agent in the cable coatings.
[0434] In particular, when the cable number ratio of PVC-type electrical cables and HF-type electrical cables was 29:1, the deterioration of the HF-type electrical cable tended to be very strong. This may be caused by the fact that the plasticizer and the like contained in the cable coatings of PVC-type electrical cables moved into the coatings of HF-type electrical cables.
[0435] By comparison, the HF-type electrical cables in-wire harnesses of Examples W49 to W54 did not form any crack by the mandrel-winding tests. In the PVC-type adhesive tapes (with copper damage inhibitor) of Examples 13 to 18, the adhesive and tape base contained an adsorbent, which adsorbed the adhesive-side deterioration accelerators and tape base-side deterioration accelerators and prevented them from moving into the cable coatings. The presence of copper damage inhibitor in the adhesive and tape base also produced a great effect.
[0436] However, in this case also, the plasticizers and the like contained in the cable coatings of PVC-type electrical cables may move into the cable coatings of HF-type electrical cables, thereby causing the deterioration of the HF-type electrical cables due to the agent migration between the electrical cables. The fact that this did not happen in the Examples of the invention indicates that the copper damage inhibitor in the PVC-type adhesive tape moved into the cable coatings of HF-type electrical cables, thereby supplying the copper damage inhibitor to the cable coatings.
[0437] As to the ease of wrapping operation and gluing capacity, the PVC-type adhesive tapes (with copper damage inhibitor) of Comparative Examples 5 and 6 were judged as defective, the reason for this deficiency being probably that they contained an excess amount of adsorbent. By comparison, the PVC-type adhesive tapes (with copper damage inhibitor) of Examples 13 to 18 were found good in ease of wrapping operation and gluing capacity, the reason therefor being that they contained the adsorbent in a suitable amount. There was no particular problem of tape appearance. The Examples of the invention were evaluated as globally good (indicated by “O” in Tables).
[0438] (10) (Mixed Cable Bundle of PVC-Type Electrical Cables and HF-Type Electrical Cables)×HF-Type Adhesive Tape (with Copper Damage Inhibitor)
[0439] Table 44 shows the results of the tests carried out with a (mixed cable bundle of PVC-type electrical cables and HF-type electrical cables)×HF-type adhesive tape (with copper damage inhibitor). As to the mandrel-winding test, cracks were found in the HF-type electrical cables in the wire harness (cable number ratio of 29:1, 20:10 and 1:29) of Prior Art W10, and the latter was evaluated as defective. It was understood that the adhesive-side deterioration accelerators and the tape base-side deterioration accelerators moved into the cable coatings of HF-type electrical cables, thereby causing the copper damage and decrease of anti-oxidizing agent in the cable coatings.
[0440] In particular, when the cable number ratio of PVC-type electrical cables and HF-type electrical cables was 29:1, the deterioration of the HF-type electrical cable tended to be very strong. This may be caused by the fact that the plasticizer and the like contained in the cable coatings of PVC-type electrical cables moved into the cable coatings of HF-type electrical cables.
[0441] Further, the HF-type adhesive tape itself of Prior Art 4 formed cracks, and was judged defective. This cracking was caused by the fact that the adhesive-side deterioration accelerators moved into the tape base.
[0442] By comparison, the HF-type electrical cables in wire harnesses of Examples W55 to W60 did not form any crack by the mandrel-winding tests. In the HF-type adhesive tapes (with copper damage inhibitor) of Examples 19 to 24, the adhesive and tape base contained an adsorbent, which adsorbed the adhesive-side deterioration accelerators and tape base-side deterioration accelerators and prevented them from moving into the cable coatings. The presence of copper damage inhibitor in the adhesive and tape base also produced a great effect.
[0443] However, in this case also, the plasticizers and the like contained in the cable coatings of PVC-type electrical cables may move into the cable coatings of HF-type electrical cables, thereby causing the deterioration of the HF-type electrical cables due to the agent migration between the electrical cables. The fact that this did not happen in the Examples of the invention indicates that the copper damage inhibitor in the HF-type adhesive tape moved into the cable coatings of HF-type electrical cables, thereby supplying the copper damage inhibitor to the cable coatings.
[0444] As to the ease of wrapping operation and gluing capacity, the HF-type adhesive tapes (with copper damage inhibitor) of Comparative Examples 7 and 8 were judged as defective, the reason for this deficiency being probably that they contained an excess amount of adsorbent. By comparison, the HF-type adhesive tapes (with copper damage inhibitor) of Examples 19 to 24 were found good in ease of wrapping operation and gluing capacity, the reason for this being that they contained the adsorbent in a suitable amount. There was no particular problem of tape appearance. The Examples of the invention were evaluated as globally good (indicated by “O” in Tables).
[0445] (11) (Mixed Cable Bundle of PVC-Type Electrical Cables and HF-Type Electrical Cables)×PVC-Type Adhesive Tape (with Anti-Oxidizing Agent and Copper Damage Inhibitor)
[0446] Table 45 shows the results of the tests carried out with a (mixed cable bundle of PVC-type electrical cables and HF-type electrical cables)×PVC-type adhesive tape (with anti-oxidizing agent and copper damage inhibitor). As to the mandrel-winding test, cracks were found in the HF-type electrical cables in the wire harness (cable number ratio of 29:1, 20:10 and 1:29) of Prior Art W11, and the latter was evaluated as defective. It was understood that the adhesive-side deterioration accelerators and the tape base-side deterioration accelerators moved into the cable coatings of HF-type electrical cables, thereby causing the copper damage and decrease of anti-oxidizing agent in the cable coatings.
[0447] In particular, when the cable number ratio of PVC-type electrical cables and HF-type electrical cables was 29:1, the deterioration of the HF-type electrical cable tended to be very strong. This may be caused by the fact that the plasticizer and the like contained in the cable coatings of PVC-type electrical cables moved into the coatings of HF-type electrical cables.
[0448] By comparison, the HF-type electrical cables in wire harnesses of Examples W61 to W66 did not form any crack by the mandrel-winding tests. The presence of an adsorbent in the adhesive and tape base, the use of a specific resin as adhesive adjuvant in the adhesive, as well as the presence of an anti-oxidizing agent and copper damage inhibitor in the adhesive and tape base, apparently produced a synergic effect.
[0449] However, in this case also, the plasticizers and the like contained in the cable coatings of PVC-type electrical cables may move into the cable coatings of HF-type electrical cables, thereby causing the deterioration of the HF-type electrical cables due to the agent migration between the electrical cables. The fact that this did not happen in the Examples of the invention indicates that the anti-oxidizing agent and copper damage inhibitor in the PVC-type adhesive tape moved into the cable coatings of HF-type electrical cables, thereby supplying the anti-oxidizing agent and copper damage inhibitor to the cable coatings.
[0450] As to the ease of wrapping operation and gluing capacity, the PVC-type adhesive tapes (with anti-oxidizing agent and copper damage inhibitor) of Comparative Examples 9 and 10 were judged as defective, the reason for this deficiency being probably that they contained an excess amount of adsorbent. By comparison, the PVC-type adhesive tapes (with anti-oxidizing agent and copper damage inhibitor) of Examples 25 to 30 were found good in ease of wrapping operation and gluing capacity, the reason for this being that they contained the adsorbent in a suitable amount. There was no particular problem for tape appearance. The Examples of the invention were evaluated as globally good (indicated by “O” in Tables)
[0451] (12) (Mixed Cable Bundle of PVC-Type Electrical Cables and HF-Type Electrical Cables)×HF-Type Adhesive Tape (with Anti-Oxidizing Agent and Copper Damage Inhibitor)
[0452] Table 46 shows the results of the tests carried out with a (mixed cable bundle of PVC-type electrical cables and HF-type electrical cables)×HF-type adhesive tape (with anti-oxidizing agent and copper damage inhibitor). As to the mandrel-winding test, cracks were found in the HF-type electrical cables in the wire harness (cable number ratio of 29:1, 20:10 and 1:29) of Prior Art W12, and the latter was evaluated as defective. It was understood that the adhesive-side deterioration accelerators and the tape base-side deterioration accelerators moved into the cable coatings of HF-type electrical cables, thereby causing the copper damage and decrease of anti-oxidizing agent in the cable coatings.
[0453] In particular, when the cable number ratio of PVC-type electrical cables and HF-type electrical cables was 29:1, the deterioration of the HF-type electrical cable tended to be very strong. This may be caused by the fact that the plasticizer and the like contained in the cable coatings of PVC-type electrical cables moved into the cable coatings of HF-type electrical cables.
[0454] Further, the HF-type adhesive tape itself of Prior Art 6 formed cracks, and was judged defective. This cracking was caused by the fact that the adhesive-side deterioration accelerators moved into the tape base.
[0455] By comparison, the HF-type electrical cables in wire harnesses of Examples W67 to W72 did not form any crack by the mandrel-winding tests. The presence of an adsorbent in the adhesive and tape base, the use of a specific resin as adhesive adjuvant in the adhesive, as well as the presence of an anti-oxidizing agent and copper damage inhibitor in the adhesive and tape base, apparently produced a synergic effect.
[0456] However, in this case also, the plasticizers and the like contained in the cable coatings of PVC-type electrical cables may move into the cable coatings of HF-type electrical cables, thereby causing the deterioration of the HF-type electrical cables due to the agent migration between the electrical cables. The fact that this did not happen in the Examples of the invention indicates that the anti-oxidizing agent and copper damage inhibitor in the HF-type adhesive tape moved into the cable coatings of HF-type electrical cables, thereby supplying the anti-oxidizing agent and copper damage inhibitor to the cable coatings.
[0457] As to the ease of wrapping operation and gluing capacity, the HF-type adhesive tapes (with anti-oxidizing agent and copper damage inhibitor) of Comparative Examples 11 and 12 were judged as defective, the reason for this deficiency being probably that they contained an excess amount of adsorbent. By comparison, the HF-type adhesive tapes (with anti-oxidizing agent and copper damage inhibitor) of Examples 31 to 36 were found good in ease of wrapping operation and gluing capacity, the reason therefor being that they contained the adsorbent in a suitable amount. There was no particular problem of tape appearance. The Examples of the invention were evaluated as globally good (indicated by “O” in Tables).
[0458] (13) [Mixed Cable Bundle of PVC-Type Electrical Cables (with Anti-Oxidizing Agent) and HF-Type Electrical Cables]×PVC-Type Adhesive Tape (with Anti-Oxidizing Agent)
[0459] Table 47 shows the results of the tests carried out with a [mixed cable bundle of PVC-type electrical cables (with anti-oxidizing agent) and HF-type electrical cables]×PVC-type adhesive tape (with anti-oxidizing agent). As to the mandrel-winding test, cracks were found in the HF-type electrical cables in the wire harness (cable number ratio of 29:1, 20:10 and 1:29) of Prior Art W13, and the latter was evaluated as defective. It was understood that the adhesive-side deterioration accelerators and the tape base-side deterioration accelerators moved into the cable coatings of HF-type electrical cables, thereby causing the copper damage and decrease of anti-oxidizing agent in the cable coatings.
[0460] By comparison, the HF-type electrical cables in wire harnesses of Examples W73 to W78 did not form any crack by the mandrel-winding tests. In the PVC-type adhesive tapes (with anti-oxidizing agent) of Examples 1 to 6, the adhesive and tape base contained an adsorbent, which adsorbed the adhesive-side deterioration accelerators and tape base-side deterioration accelerators and prevented them from moving into the cable coatings. The presence of anti-oxidizing agent in the adhesive and tape base also produced a great effect.
[0461] Moreover, in the present Examples, PVC-type electrical cables containing an anti-oxidizing agent were used. Accordingly, even if the plasticizers and the like contained in the cable coatings of PVC-type electrical cables moved into the cable coatings of HF-type electrical cables, the deterioration of the cable coatings of HF-type electrical cables, owing to the agent migration between the electrical cables, could be efficiently prevented.
[0462] As to the ease of wrapping operation and gluing capacity, the PVC-type adhesive tapes (with anti-oxidizing agent) of Comparative Examples 1 and 2 were judged as defective, the reason for this deficiency being probably that they contained an excess amount of adsorbent. By comparison, the PVC-type adhesive tapes (with anti-oxidizing agent) of Examples 1 to 6 were found good in ease of wrapping operation and gluing capacity, the reason for this being that they contained the adsorbent in a suitable amount. The Examples of the invention were evaluated as globally good (indicated by “O” in Tables).
[0463] (14) (Mixed Cable Bundle of PVC-Type Electrical Cables (with Anti-Oxidizing Agent) and HF-Type Electrical Cables)×HF-Type Adhesive Tape (with Anti-Oxidizing Agent)
[0464] Table 48 shows the results of the tests carried out with a [mixed cable bundle of PVC-type electrical cables (with anti-oxidizing agent) and HF-type electrical cables]×HF-type adhesive tape (with anti-oxidizing agent). As to the mandrel-winding test, cracks were found in the HF-type electrical cables in the wire harness (cable number ratio of 29:1, 20:10 and 1:29) of Prior Art W14, and the latter was evaluated as defective. It was understood that the adhesive-side deterioration accelerators and the tape base-side deterioration accelerators moved into the cable coatings of HF-type electrical cables, thereby causing the copper damage and decrease of anti-oxidizing agent in the cable coatings.
[0465] Further, the HF-type adhesive tape itself of Prior Art 2 formed cracks, and was judged as failed. This cracking was caused by the migration of the adhesive-side deterioration accelerators into the tape base.
[0466] By comparison, the HF-type electrical cables in wire harnesses of Examples W79 to W84 did not form any crack by the mandrel-winding tests. In the HF-type adhesive tapes (with anti-oxidizing agent) of Examples 7 to 12, the adhesive and tape base contained an adsorbent, which adsorbed the adhesive-side deterioration accelerators and tape base-side deterioration accelerators and prevented them from moving into the cable coatings. The presence of anti-oxidizing agent in the adhesive and tape base also produced a great effect.
[0467] Moreover, in the present Examples, PVC-type electrical cables containing an anti-oxidizing agent were used. Accordingly, even if the plasticizers and the like contained in the cable coatings of PVC-type electrical cables move into the cable coatings of HF-type electrical cables, the deterioration of the cable coatings of HF-type electrical cables, owing to the agent migration between the electrical cables, could be efficiently prevented.
[0468] As to the ease of wrapping operation and gluing capacity, the HF-type adhesive tapes (with anti-oxidizing agent) of Comparative Examples 3 and 4 were judged as defective, the reason for this deficiency being probably that they contained an excess amount of adsorbent. By comparison, the HF-type adhesive tapes (with anti-oxidizing agent) of Examples 7 to 12 were found good in ease of wrapping operation and gluing capacity, the reason for this being that they contained the adsorbent in a suitable amount. The Examples of the invention were evaluated as globally good (indicated by “O” in Tables).
[0469] (15) [Mixed Cable Bundle of PVC-Type Electrical Cables (with Anti-Oxidizing Agent) and HF-Type Electrical Cables]×PVC-Type Adhesive Tape (with Copper Damage Inhibitor)
[0470] Table 49 shows the results of the tests carried out with a [mixed cable bundle of PVC-type electrical cables (with anti-oxidizing agent) and HF-type electrical cables]×PVC-type adhesive tape (with copper damage inhibitor). As to the mandrel-winding test, cracks were found in the HF-type electrical cables in the wire harness (cable number ratio of 29:1, 20:10 and 1:29) of Prior Art W15, and the latter was evaluated as defective. It was understood that the adhesive-side deterioration accelerators and the tape base-side deterioration accelerators moved into the cable coatings of HF-type electrical cables, thereby causing the copper damage and decrease of anti-oxidizing agent in the cable coatings.
[0471] By comparison, the HF-type electrical cables in wire harnesses of Examples W85 to W90 did not form any crack by the mandrel-winding tests. In the PVC-type adhesive tapes (with copper damage inhibitor) of Examples 13 to 18, the adhesive and tape base contained an adsorbent, which adsorbed the adhesive-side deterioration accelerators and tape base-side deterioration accelerators and prevented them from moving into the cable coatings. The presence of copper damage inhibitor in the adhesive and tape base also produced a great effect.
[0472] Moreover, in the present Examples, PVC-type electrical cables containing an anti-oxidizing agent were used. Accordingly, even if the plasticizers and the like contained in the cable coatings of PVC-type electrical cables move into the cable coatings of HF-type electrical cables, the deterioration of the cable coatings of HF-type electrical cables, owing to the agent migration between the electrical cables, could be efficiently prevented.
[0473] As to the ease of wrapping operation and gluing capacity, the PVC-type adhesive tapes (with copper damage inhibitor) of Comparative Examples 5 and 6 were judged as defective, the reason for this deficiency being probably that they contained an excess amount of adsorbent. By comparison, the PVC-type adhesive tapes (with copper damage inhibitor) of Examples 13 to 18 were found good in ease of wrapping operation and giuing capacity, the reason for this being that they contained the adsorbent in a suitable amount. There was no particular problem for tape appearance. The Examples of the invention were evaluated as globally good (indicated by “O” in Tables).
[0474] (16) [Mixed Cable Bundle of PVC-Type Electrical Cables (with anti-Oxidizing Agent) and HF-Type Electrical Cables]×HF-Type Adhesive Tape (with Copper Damage Inhibitor)
[0475] Table 50 shows the results of the tests carried out with a [mixed cable bundle of PVC-type electrical cables (with anti-oxidizing agent) and HF-type electrical cables]×HF-type adhesive tape (with copper damage inhibitor). As to the mandrel-winding test, cracks were found in the HF-type electrical cables in the wire harness (cable number ratio of 29:1, 20:10 and 1:29) of Prior Art W16, and the latter was evaluated as defective. It was understood that the adhesive-side deterioration accelerators and the tape base-side deterioration accelerators moved into the cable coatings of HF-type electrical cables, thereby causing the copper damage and decrease of anti-oxidizing agent in the cable coatings.
[0476] The HF-type adhesive tape itself of Prior Art 4 formed cracks, and considered to be failed. This cracking was caused by the migration of the adhesive-side deterioration accelerators into the tape base.
[0477] By comparison, the HF-type electrical cables in wire harnesses of Examples W91 to W96 did not form any crack by the mandrel-winding tests. In the HF-type adhesive tapes (with copper damage inhibitor) of Examples 19 to 24, the adhesive and tape base contained an adsorbent, which adsorbed the adhesive-side deterioration accelerators and tape base-side deterioration accelerators and prevented them from moving into the cable coatings. The presence of copper damage inhibitor in the adhesive and tape base also produced a great effect.
[0478] Moreover, in the present Examples, PVC-type electrical cables containing an anti-oxidizing agent are used. Accordingly, even if the plasticizers and the like contained in the cable coatings of PVC-type electrical cables migrate into the cable coatings of HF-type electrical cables, the deterioration of the cable coatings of HF-type electrical cables caused by the agent migration between the electrical cables could be efficiently prevented.
[0479] As to the ease of wrapping operation and gluing capacity, the HF-type adhesive tapes (with copper damage inhibitor) of Comparative Examples 7 and 8 were judged as defective, the reason for this failure being probably that they contained an excess amount of adsorbent. By comparison, the HF-type adhesive tapes (with copper damage inhibitor) of Examples 19 to 24 were found good in ease of wrapping operation and gluing capacity, the reason therefor being that they contained the adsorbent in a suitable amount. There was no particular problem of tape appearance. The Examples of the invention were evaluated as globally good (indicated by “O” in Tables).
[0480] (17) [Mixed Cable Bundle of PVC-Type Electrical Cables (with Anti-(Oxidizing Agent) and HF-Type Electrical Cables]×PVC-Type Adhesive Tape (with Anti-Oxidizing Agent and Copper Damage Inhibitor)
[0481] Table 51 shows the results of the tests carried out with a [mixed cable bundle of PVC-type electrical cables (with anti-oxidizing agent) and HF-type electrical cables]×PVC-type adhesive tape (with anti-oxidizing agent and copper damage inhibitor). As to the mandrel-winding test, cracks were found in the HF-type electrical cables in the wire harness (cable number ratio of 29:1, 20:10 and 1:29) of Prior Art W17, and the latter was evaluated as defective. It was understood that the adhesive-side deterioration accelerators and the tape base-side deterioration accelerators moved into the cable coatings of HF-type electrical cables, thereby causing the copper damage and decrease of anti-oxidizing agent in the cable coatings.
[0482] By comparison, the HF-type electrical cables in wire harnesses of Examples W97 to W102 did not form any crack by the mandrel-winding tests. The presence of adsorbent in the adhesive and tape base, the use of a specific resin as adhesive adjuvant in the adhesive, as well as the presence of anti-oxidizing agent and copper damage inhibitor in the adhesive and tape base, apparently produced a synergic effect.
[0483] Moreover, in the present Examples, PVC-type electrical cables containing an anti-oxidizing agent were used. Accordingly, even if the plasticizers and the like contained in the cable coatings of PVC-type electrical cables move into the cable coatings of HF-type electrical cables, the deterioration of the cable coatings of HF-type electrical cables, owing to the agent migration between the electrical cables, could be efficiently prevented.
[0484] As to the ease of wrapping operation and gluing capacity, the PVC-type adhesive tapes (with anti-oxidizing agent and copper damage inhibitor) of Comparative Examples 9 and 10 were judged as defective, the reason for this deficiency being probably that they contained an excess amount of adsorbent. By comparison, the PVC-type adhesive tapes (with anti-oxidizing agent and copper damage inhibitor) of Examples 25 to 30 were found good in ease of wrapping operation and gluing capacity, the reason therefor being that they contained the adsorbent in a suitable amount. There was no particular problem of tape appearance. The Examples of the invention were evaluated as globally good (indicated by “O” in Tables).
[0485] (18) [Mixed Cable Bundle of PVC-Type Electrical Cables (with Anti-Oxidizing Agent) and HF-Type Electrical Cables]×HF-Type Adhesive Tape (with Anti-Oxidizing Agent and Copper Damage Inhibitor)
[0486] Table 52 shows the results of the tests carried out with a [mixed cable bundle of PVC-type electrical cables (with anti-oxidizing agent) and HF-type electrical cables]×HF-type adhesive tape (with anti-oxidizing agent and copper damage inhibitor). As to the mandrel-winding test, cracks were found in the HF-type electrical cables in the wire harness (cable number ratio of 29:1, 20:10 and 1:29) of Prior Art W18, and the latter was evaluated as defective. It was understood that the adhesive-side deterioration accelerators and the tape base-side deterioration accelerators moved into the cable coatings of HF-type electrical cables, thereby causing the copper damage and decrease of anti-oxidizing agent in the cable coatings.
[0487] The HF-type adhesive tape itself of Prior Art 6 formed cracks, and considered to be failed. This cracking was caused by the migration of the adhesive-side deterioration accelerators into the tape base.
[0488] By comparison, the HF-type electrical cables in wire harnesses of Examples W103 to W108 did not form any crack by the mandrel-winding tests. The presence of adsorbent in the adhesive and tape base, the use of a specific resin as adhesive adjuvant in the adhesive, as well as the presence of anti-oxidizing agent and copper damage inhibitor in the adhesive and tape base, apparently produced a synergic effect.
[0489] Moreover, in the present Examples, PVC-type electrical cables containing an anti-oxidizing agent were used. Accordingly, even if the plasticizers and the like contained in the cable coatings of PVC-type electrical cables move into the cable coatings of HF-type electrical cables, the deterioration of the cable coatings of HF-type electrical cables, owing to the migration of the agent between the electrical cables, could be efficiently prevented.
[0490] As to the ease of wrapping operation and gluing capacity, the HF-type adhesive tapes (with anti-oxidizing agent and copper damage inhibitor) of Comparative Examples 11 and 12 were judged as defective, the reason for this failure being probably that they contained an excess amount of adsorbent. By comparison, the HF-type adhesive tapes (with anti-oxidizing agent and copper damage inhibitor) of Examples 31 to 36 were found good in ease of wrapping operation and gluing capacity, the reason for this being that they contained the adsorbent in a suitable amount. There was no particular problem of tape appearance. The Examples of the invention were evaluated as globally good (indicated by “O” in Tables).
[0491] The above embodiment was explained using a particular adsorbent, adhesive adjuvant made of specific resin, an anti-oxidizing agent, a copper damage inhibitor and/or a filler. However, the invention is not limited to the above particular compounds, and other additives may also be used.
[0492] In the above embodiment, a cable bundle containing PVC-type electrical cables only (PVC-type plain bundle) and the wire harness comprising this cable bundle were not specifically mentioned. However, the invention can also be applied to such a cable bundle and wire harness.
[0493] According to the harness-protecting material of the invention, the copper damage caused by the migration of the adhesive-side and the tape base-side deterioration accelerators, as well as the decrease of the anti-oxidizing agent in the cable coatings, are efficiently prevented. As a result, when a wire harness comprises such a harness-protecting material e.g. in the form of a tape, the electrical cables contained in the cable bundles of wire harness, in particular, those coated with a HF-type resin, are protected from rapid deterioration. Such a wire harness can provide a durable good quality.
[0494] When such a wire harness is used in severe environments, e.g. near the automobile engines, it shows a remarkable reliability, creating thus a great industrial advantage.
[0495] Embodiment 3
[0496] There were provided 5 types of cable bundle coated with the harness-protecting material of the invention. A first type relates to a HF-type plain cable bundle containing 30 units of HF-type electrical cables referred to in Table 1. The other 4 types relate to a mixed cable bundle composed of HF-type electrical cables referred to in Table 1 and PVC-type electrical cables referred to in Table 2 or PVC-type anti-oxidizing electrical cables referred to in Table 3. Each type of cable bundles contained 30 electrical cables in total. In the mixed cable bundles, the cable number ratio of PVC-type electrical cables to HF-type electrical cables was 25:5, 20:10, 10:20 and 5:25, respectively.
[0497] Adhesive tapes were used as harness-protecting material for the following embodiment. The tape base was formed of PVC resin containing an adsorbent, one whole face of the tape base was coated with an adhesive made of acrylic acid resin emulsion containing an adsorbent, so as to prepare a PVC-type adhesive tape. Tables 53, 54 and 55 show Experiments 1 to 3, which comprise the compositions of the PVC-type adhesive tapes thus prepared and test results effected with these tapes. In Experiment 1, the adhesive and tape base of the PVC-type adhesive tape contained, inter alia, an anti-oxidizing agent In Experiment 2, the adhesive and tape base contained, inter alia, a copper damage inhibitor. In Experiment 3, the adhesive and tape base contained, inter alia, an anti-oxidizing agent and a copper damage inhibitor. In all cases, the adhesive had a thickness of 0.02 mm, and the adhesive and tape base had a total thickness of 0.13 mm.
[0498] As to the adhesive of the PVC-type adhesive tapes of Experiment 1 referred to in Table 53, Prior Art Example contained 70 parts by weight of styrene butadiene rubber (SBR), 30 parts by weight of natural rubber (NR), 20 parts by weight of zinc white and 80 parts by weight of rosin-type resin. Examples 1-1 to 1-6 contained 100 parts by weight of acrylic acid resin emulsion, 1, 10 or 150 parts by weight (suitable amount) of adsorbent (carbon black or silica) and 3 parts by weight of anti-oxidizing agent. Comparative Examples 1-1 and 1-2 contained 100 parts by weight of acrylic acid resin emulsion, 160 parts by weight (excessive amount) of adsorbent (carbon black or silica) and 3 parts by weight of anti-oxidizing agent.
[0499] As to the tape base, Prior Art Example contained 100 parts by weight of PVC (P: 1300), 60 parts by weight of DOP as plasticizer, 20 parts by weight of calcium carbonate as fillers and 5 parts by weight of zinc-calcium-type compound as stabilizer. Compared to this, Examples 1-1 to 1-6 further contained 1, 10 or 150 parts by weight (suitable amount) of adsorbent (carbon black or silica) and 5 parts by weight of anti-oxidizing agent. Likewise, Comparative Examples 1-1 and 1-2 further contained, compared to Prior Art Example, 160 parts by weight (excessive amount) of adsorbent (carbon black or silica) and 5 parts by weight of anti-oxidizing agent.
[0500] As to the adhesive of the PVC-type adhesive tapes of Experiment 2 referred to in Table 54, Prior Art Example contained 70 parts by weight of styrene butadiene rubber (SBR), 30 parts by weight of natural rubber (NR), 20 parts by weight of zinc white and 80 parts by weight of rosin-type resin. Examples 1-1 to 1-6 contained 100 parts by weight of acrylic acid resin emulsion, 1, 10 or 150 parts by weight (suitable amount) of adsorbent (carbon black or silica) and 1 part by weight of copper damage inhibitor. Comparative Examples 2-1 and 2-2 contained 100 parts by weight of acrylic acid resin emulsion, 160 parts by weight (excessive amount) of adsorbent (carbon black or silica) and 1 part by weight of copper damage inhibitor.
[0501] As to the tape base, Prior Art Example contained 100 parts by weight of PVC (P: 1300), 60 parts by weight of DOP as plasticizer, 20 parts by weight of calcium carbonate as fillers and 5 parts by weight of zinc-calcium-type compound as stabilizer. Compared to this, Examples 2-1 to 2-6 further contained 1, 10 or 150 parts by weight (suitable amount) of adsorbent (carbon black or silica) and 1.6 parts by weight of copper damage inhibitor. Likewise, Comparative Examples 2-1 and 2-2 further contained, compared to Prior Art Example, 160 parts by weight (excessive amount) of adsorbent (carbon black or silica) and 1.6 parts by weight of copper damage inhibitor.
[0502] As to the adhesive of the PVC-type adhesive tapes of Experiment 3 referred to in Table 55, Prior Art Example contained 70 parts by weight of styrene butadiene rubber (SBR), 30 parts by weight of natural rubber (NR), 20 parts by weight of zinc white and 80 parts by weight of rosin-type resin. Examples 3-1 to 3-6 contained 100 parts by weight of acrylic acid resin emulsion, 1, 10 or 150 parts by weight (suitable amount) of adsorbent (carbon black or silica), 3 parts by weight of anti-oxidizing agent and 1 part by weight of copper damage inhibitor. Comparative Examples 3-1 and 3-2 contained 100 parts by weight of acrylic acid resin emulsion, 160 parts by weight (excessive amount) of adsorbent (carbon black or silica), 3 parts by weight of anti-oxidizing agent and 1 part by weight of copper damage inhibitor.
[0503] As to the tape base, Prior Art Example contained 100 parts by weight of PVC (P: 1300), 60 parts by weight of DOP as plasticizer, 20 parts by weight of calcium carbonate as fillers and 5 parts by weight of zinc-calcium-type compound as stabilizer. Compared to this, Examples 3-1 to 3-6 further contained 1, 10 or 150 parts by weight (suitable amount) of adsorbent (carbon black or silica), 5 parts by weight of anti-oxidizing agent and 1.6 parts by weight of copper damage inhibitor. Likewise, Comparative Examples 3-1 and 3-2 further contained, compared to Prior Art Example, 160 parts by weight (excessive amount) of adsorbent (carbon black or silica), 5 parts by weight of anti-oxidizing agent and 1.6 parts by weight of copper damage inhibitor.
[0504] In other words, in Experiments 1 to 3 referred to in Tables 53 to 55, the adhesive of the PVC-type adhesive tapes contained, in common, an emulsion-type acrylic acid resin and an adsorbent, whereas the tape base thereof contained an adsorbent in common. Experiment 2 corresponded to Experiment 1 in which the anti-oxidizing agent was replaced by the copper damage inhibitor. Likewise, Experiment 3 corresponded to Experiment 1 (or Experiment 2) in which the anti-oxidizing agent (or copper damage inhibitor) was replaced by the anti-oxidizing agent and copper damage inhibitor.
[0505] In Experiments 1 and 3, the anti-oxidizing agent was added in a proportion of about 3 parts by weight relative to 100 parts by weight of resin component, which is equivalent to the ratio used for HF-type electrical cables referred to in Table 1. Accordingly, for the adhesive, the addition of anti-oxidizing agent was designed to be 3 parts by weigh relative to 100 parts by weight of base organic material portion (acrylic acid resin emulsion), whereas, for the tape base, it was added in a proportion of 5 parts by weight relative to 160 parts by weight of base organic material portion (PVC+DOP), so that the weight ratio becomes 3.12:100. Likewise, in Experiments 2 and 3, the copper damage inhibitor was added in a proportion of about 1 part by weight relative to 100 parts by weight of base organic material portion, which is equivalent to the ratio used for HF-type electrical cables referred to in Table 1. Accordingly, for the adhesive, the addition of copper damage inhibitor was designed to be 1 part by weight relative to 100 parts by weight of base organic material portion (acrylic acid resin emulsion), whereas, for the tape base, it was added in a proportion of 1.6 parts by weight relative to 160 parts by weight of resin component (PVC+DOP), so that the weight ratio becomes 1:100.
[0506] The Prior Art Examples, Examples and Comparative Examples prepared according to the compositions referred to in Tables 53 to 55 were subjected to the tests and the evaluations of the results obtained.
[0507] One face of each of PVC tape base was painted with the adhesive, and the adhesive-painted face was wrapped around 5 types of cable bundles i.e. HF-type plain cable bundles and mixed cable bundles (see FIG. 2( c )). The prepared samples were allowed to stand for 96 hours in a thermostatically controlled environment at 150° C. The HF-type electrical cables were then taken out from the thermostat and wound around a mandrel of φ 10 mm. The cable coatings were subjected to observations on whether cracks were formed and on the winding ease.
[0508] The test results mentioned in Tables 53 to 55 were only classified as a function of the resin composition, but not of the type of cable bundle, since the type of cable bundle or its mixture ratio did not affect the test results. According to these results, Prior Art Example of the PVC-type tape whose one face is painted with the adhesive showed a good operational ease on winding, but formed cracks in the HF-type electrical cables (indicated “X” as bad result). Comparative Examples 1-1, 1-2, 2-1, 2-2, 3-1 and 3-2 formed no crack in the HF-type electrical cables, but showed difficulty in winding operation, and were judged as failed. Examples 1-1 to 1-6, 2-1 to 2-6 and 3-1 to 3-6 formed no crack and enabled an easy winding operation, and were therefore judged as globally good (“O”). The test results did not differ between the taped portion A of the cable bundle and its non-taped portion B (FIG. 2).
[0509] As mentioned above, the adhesive comprised an acrylic acid resin emulsion, an adsorbent, and an anti-oxidizing agent and/or a copper damage inhibitor, and the tape base was formed of a PVC resin material comprising an adsorbent, and an anti-oxidizing agent and/or a copper damage inhibitor. The adhesive was then painted on one whole face of the tape base, so as to prepare an adhesive tape. When this adhesive tape was wound around a HF-type plain cable bundle or a HF-type mixed cable bundle (cable: soft copper wires), the formed HF-type electrical cables formed no crack, and their anti-hot oxidation property was prevented from degradation.
[0510] The reasons for such improved results can be explained as follows.
[0511] First, the emulsion-type acrylic acid resin used as main component of the adhesive has a molecular weight far larger than the commonly used materials, and is comparatively less mobile and less prone to shift. As its molecular chain is long, its adhesive capacity is high, so that the adhesive made therefrom does not require the addition of plasticizers. Accordingly, the phenomenon of plasticizer migration, observed in the adhesive, can be suppressed.
[0512] Secondly, because of its long molecular chain and high viscosity, the emulsion-type acrylic acid resin used in the adhesive blocks the plasticizers in the tape base and prevents them from moving into the cable bundles.
[0513] Third, the emulsion-type acrylic acid resin and plasticizers contained in the adhesive-painted tape (PVC protector material) are adsorbed by an adsorbent, so that they are prevented from moving into the HF-type electrical cables. In the adhesive itself, the emulsion-type acrylic acid resin, already not so mobile, is adsorbed by an adsorbent, and is rendered further less mobile.
[0514] Fourth, by virtue to the immobilization of the emulsion-type acrylic acid resin and plasticizers, the plasticizers cannot dissolve the anti-oxidizing agent and copper damage inhibitor initially contained in the HF-type electrical cables, and carry them into the PVC protector material.
[0515] Fifth, the PVC protector material (adhesive-painted tape) contains an anti-oxidizing agent and/or a copper damage inhibitor in a suitable amount, so that their amount ratio in the PVC protector material is about the same as the ratio initially maintained in the HF-type electrical cables. Accordingly, there forms little concentration gradient of the anti-oxidizing agent and/or copper damage inhibitor between the HF-type electrical cables and the PVC protector material, so that the agents are prevented from diffusing from the HF-type electrical cables into the PVC protector material.
[0516] Sixth, the immobilization of the emulsion-type acrylic acid resin and plasticizers and the non-diffusion of the anti-oxidizing agent and/or copper damage inhibitor produce a synergic effect.
[0517] The tape base was formed of a HF resin containing an adsorbent, one whole face of the tape base was coated with an adhesive made of acrylic acid resin emulsion containing an adsorbent, so as to prepare a HF-type adhesive-painted tape. Tables 56, 57 and 58 show Experiments 4 to 6, which comprise the compositions of the HF-type adhesive tapes thus prepared and test results effected with these tapes. In Experiment 4, the adhesive and tape base of the HF-type adhesive tape contained, inter alia, an anti-oxidizing agent In Experiment 5, the adhesive and tape base contained, inter alia, a copper damage inhibitor. In Experiment 6, the adhesive and tape base contained, inter alia, an anti-oxidizing agent and a copper damage inhibitor. In all cases, the adhesive had a thickness of 0.02 mm, and the adhesive and tape base had a total thickness of 0. 13 mm.
[0518] As to the adhesive of the HF-type adhesive tapes of Experiment 4 referred to in Table 56, Prior Art Example contained 70 parts by weight of styrene butadiene rubber (SBR), 30 parts by weight of natural rubber (NR), 20 parts by weight of zinc white and 80 parts by weight of rosin-type resin. Examples 4-1 to 4-6 contained 100 parts by weight of acrylic acid resin emulsion, 1, 10 or 150 parts by weight (suitable amount) of adsorbent (carbon black or silica) and 3 parts by weight of anti-oxidizing agent. Comparative Examples 4-1 and 4-2 contained 100 parts by weight of acrylic acid resin emulsion, 160 parts by weight (excessive amount) of adsorbent (carbon black or silica) and 3 parts by weight of anti-oxidizing agent.
[0519] As to the tape base, Prior Art Example contained 100 parts by weight of polyolefin-type resin, 3 parts by weight of bromine-type flame-retardant and 1.5 parts by weight of antimony trioxide. Compared to this, Examples 4-1 to 4-6 further contained 1, 10 or 150 parts by weight (suitable amount) of adsorbent (carbon black or silica) and 3.5 parts by weight of anti-oxidizing agent. Likewise, Comparative Examples 4-1 and 4-2 further contained, compared to Prior Art Example, 160 parts by weight (excessive amount) of adsorbent (carbon black or silica) and 3.5 parts by weight of anti-oxidizing agent.
[0520] As to the adhesive of the HF-type adhesive tapes of Experiment 5 referred to in Table 57, Prior Art Example contained 70 parts by weight of styrene butadiene rubber (SBR), 30 parts by weight of natural rubber (NR), 20 parts by weight of zinc white and 80 parts by weight of rosin-type resin. Examples 5-1 to 5-6 contained 100 parts by weight of acrylic acid resin emulsion, 1, 10 or 150 parts by weight (suitable amount) of adsorbent (carbon black or silica) and 1 part by weight of copper damage inhibitor. Comparative Examples 5-1 and 5-2 contained 100 parts by weight of acrylic acid resin emulsion, 160 parts by weight (excessive amount) of adsorbent (carbon black or silica) and 1 part by weight of copper damage inhibitor.
[0521] As to the tape base, Prior Art Example contained 100 parts by weight of polyolefin-type resin, 3 parts by weight of bromine-type flame-retardant and 1.5 parts by weight of antimony trioxide. Compared to this, Examples 5-1 to 5-6 further contained 1, 10 or 150 parts by weight (suitable amount) of adsorbent (carbon black or silica) and 1 part by weight of copper damage inhibitor. Likewise, Comparative Examples 5-1 and 5-2 further contained, compared to Prior Art Example, 160 parts by weight (excessive amount) of adsorbent (carbon black or silica) and 1 part by weight of copper damage inhibitor.
[0522] As to the adhesive of the HF-type adhesive tapes of Experiment 6 referred to in Table 58, Prior Art Example contained 70 parts by weight of styrene butadiene rubber (SBR), 30 parts by weight of natural rubber (NR), 20 parts by weight of zinc white and 80 parts by weight of rosin-type resin. Examples 6-1 to 6-6 contained 100 parts by weight of acrylic acid resin emulsion, 1, 10 or 150 parts by weight (suitable amount) of adsorbent (carbon black or silica), 3 parts by weight of anti-oxidizing agent and 1 part by weight of copper damage inhibitor. Comparative Examples 6-1 and 6-2 contained 100 parts by weight of acrylic acid resin emulsion, 160 parts by weight (excessive amount) of adsorbent (carbon black or silica), 3 parts by weight of anti-oxidizing agent and 1 part by weight of copper damage inhibitor.
[0523] As to the tape base, Prior Art Example contained 100 parts by weight of polyolefin-type resin, 3 parts by weight of bromine-type flame-retardant and 1.5 parts by weight of antimony trioxide. Compared to this, Examples 6-1 to 6-6 further contained 1, 10 or 150 parts by weight (suitable amount) of adsorbent (carbon black or silica), 3.5 parts by weight of anti-oxidizing agent and 1 part by weight of copper damage inhibitor. Likewise, Comparative Examples 6-1 and 6-2 further contained, compared to Prior Art Example, 160 parts by weight (excessive amount) of adsorbent (carbon black or silica), 3.5 parts by weight of anti-oxidizing agent and 1 part by weight of copper damage inhibitor.
[0524] In other words, in Experiments 4 to 6 referred to in Tables 56 to 58, the adhesive of the HF-type adhesive tapes contained, in common, an emulsion-type acrylic acid resin and an adsorbent, whereas the tape base thereof contained an adsorbent in common. Experiment 5 corresponded to Experiment 4 in which the anti-oxidizing agent was replaced by the copper damage inhibitor. Likewise, Experiment 6 corresponded to Experiment 4 (or Experiment 5) in which the anti-oxidizing agent (or copper damage inhibitor) was replaced by the anti-oxidizing agent and copper damage inhibitor.
[0525] In Experiments 4 and 6, the anti-oxidizing agent was added in a proportion of about 3 parts by weight relative to 100 parts by weight of base organic material portion, which is equivalent to the ratio used for HF-type electrical cables referred to in Table 1. Accordingly, for the adhesive, the addition of anti-oxidizing agent was designed to be 3 parts by weigh relative to 100 parts by weight of base organic material portion (acrylic acid resin emulsion) whereas, for the tape base, it was added in a proportion of 3.5 parts by weight relative to 100 parts by weight of base organic material portion (polyolefin, the flame-retardant being disregarded). Likewise, in Experiments 5 and 6, the copper damage inhibitor was added in a proportion of about 1 part by weight relative to 100 parts by weight of base organic material portion, which is equivalent to the ratio used for HF-type electrical cables referred to in Table 1. Accordingly, for the adhesive, the addition of copper damage inhibitor was designed to be 1 part by weigh relative to 100 parts by weight of base organic material portion (acrylic acid resin emulsion) whereas, for the tape base, it was added in a proportion of 1 part by weight relative to 100 parts by weight of base organic material portion (polyolefin, the flame-retardant being disregarded).
[0526] The Prior Art Examples, Examples and Comparative Examples prepared according to the compositions referred to in Tables 56 to 58 were subjected to the tests and the evaluations of the results obtained.
[0527] One face of each of HF tape base was painted with the adhesive, and the adhesive-painted face was wrapped around 5 types of cable bundles i.e. HF-type plain cable bundles and mixed cable bundles (see FIG. 2( c )). The prepared samples were allowed to stand for 96 hours in a thermostat at 150° C. The HF-type electrical cables were then taken out from the thermostatically controlled environment and wound around a mandrel of φ 10 mm. The cable coatings were subjected to observations as to whether cracks were formed and on the winding ease.
[0528] The test results mentioned in Tables 56 to 58 were only classified as a function of the resin composition, but not of the type of cable bundle, since the type of cable bundle or its mixture ratio did not affect the test results. According to these results, Prior Art Example of the HF-type tape, of which one face was painted with the adhesive, showed a good operational ease of winding, but formed cracks in the HF-type electrical cables (indicated “X” as bad result). Comparative Examples 4-1, 4-2, 5-1, 5-2, 6-1 and 6-2 formed no crack in the HF-type electrical cables, but showed difficulty in winding operation, and were judged as failed. Examples 4-1 to 4-6, 5-1 to 5-6 and 6-1 to 6-6 formed no crack and enabled an easy winding operation, and were therefore judged as globally good (“O”). The test results did not differ between the taped portion A of the cable bundle and its non-taped portion B (FIG. 2).
[0529] As mentioned above, the adhesive comprises an acrylic acid resin emulsion, an adsorbent, and an anti-oxidizing agent and/or a copper damage inhibitor, and the tape base is formed of a polyolefin-type HF resin material comprising an adsorbent, and an anti-oxidizing agent and/or a copper damage inhibitor. The adhesive is then painted on one whole face of the tape base, so as to prepare an adhesive tape. When this adhesive tape is wound around a HF-type plain cable bundle or a HF-type mixed cable bundle (cable: soft copper wires), the formed HF-type electrical cables formed no crack, and their anti-hot oxidizing property was prevented from degradation.
[0530] As in the cases of Experiments 1 to 3, the reasons for such improved results can be explained as follows.
[0531] First, the emulsion-type acrylic acid resin used as main component of the adhesive has a molecular weight far larger than the commonly used materials, and is comparatively less mobile and less prone to shift. As its molecular chain is long, its adhesive capacity is high, so that the adhesive made therefrom does not require the addition of plasticizers. Accordingly, the phenomenon of plasticizer migration, observed in the adhesive, can be suppressed.
[0532] Secondly, because of its long molecular chain and high viscosity, the emulsion-type acrylic acid resin used in the adhesive prevents the plasticizers in the tape base from moving into the cable bundles.
[0533] Third, the emulsion-type acrylic acid resin and plasticizers contained in the adhesive-painted HF tape (HF protector material) are adsorbed by an adsorbent, so that they are prevented from moving into the HF-type electrical cables. In the adhesive itself, the emulsion-type acrylic acid resin, already not so mobile, is adsorbed by an adsorbent, and is rendered even less mobile.
[0534] Fourth, the HF protector material (adhesive-painted tape) contains an adsorbent, which may improve the anti-hot oxidizing property of the HF protector material. Carbon black used as an adsorbent improves the durability of the HF protector material, whilst silica used as an adsorbent improves the heat resistance and acid resistance of the HF protector material. As a result, the anti-hot oxidizing property of HF electrical cables is rendered durable.
[0535] Fifth, the adsorbent contained in the HF protector material (adhesive-painted tape) prevents the plasticizers in the PVC electrical cables from moving into the HF protector material. This occurs especially when a mixed cable bundle is used.
[0536] Sixth, the anti-oxidizing agent and copper damage inhibitor contained in the HF protector material (adhesive-painted tape) render the latter a kind of barrier, and protect from the effects of water in the air and of the adhesive. As a result, the anti-hot oxidizing property of HF electrical cables is prevented from degradation.
[0537] Seventh, the PVC protector material (adhesive-painted tape) contains an anti-oxidizing agent and/or a copper damage inhibitor in a suitable amount, so that their amount ratio in the PVC protector material is about the same as the ratio initially maintained in the HF-type electrical cables. Accordingly, there forms little concentration gradient of the anti-oxidizing agent and/or copper damage inhibitor between the HF-type electrical cables and the PVC protector material, so that the agents are prevented from diffusing from the HF-type electrical cables into the PVC protector material.
[0538] Eighth, the immobilization of the emulsion-type acrylic acid resin and plasticizers and the non-diffusion of the anti-oxidizing agent and/or copper damage inhibitor produce a synergic effect.
[0539] Although the above embodiment is explained using a harness-protecting material made of PVC-type resin or polyolefin-type resin, the resin composition of the invention is not limited to the above resin.
[0540] The invention relates to a harness-protecting material, e.g. tape painted with an adhesive, and the adhesive containing an acrylic acid resin. In such case, when HF-type electrical cables are used alone, or they are used in a mixture with PVC-type electrical cables, the HF-type electrical cables and harness-protecting material can avoid the degrading effect of the PVC-type electrical cables. The electrical cables in the wire harness thus maintain a good and stable quality, and secure a long and durable use.
[0541] In the above harness-protecting material, the adhesive painted on the surface of the tape base contains an acrylic acid-type resin as base polymer portion which is less prone to move, and the harness-protecting material can maintain a good anti-hot oxidizing property. As a result, the insulated HF electrical cables are prevented from the deterioration of its anti-hot oxidizing property.
[0542] In the above harness-protecting material, the tape base and/or adhesive contain(s) an adsorbent. When the tape base is formed of a PVC-type resin, the adsorbent adsorbs the plasticizer and the acrylic acid resin. When the tape base is formed of a HF-type resin, the adsorbent improves the durability, heat resistance and acid resistance of the harness-protecting material. Accordingly, the harness-protecting material can maintain its good anti-hot oxidizing property. As a result, the insulated HF electrical cables are protected from the degradation of its anti-hot oxidizing quality.
[0543] In the above harness-protecting material, the tape base and/or adhesive further contain(s) an anti-oxidizing agent and/or a copper damage inhibitor. The presence of these agent(s) in the tape base and/or adhesive prevents those contained in the cable coatings of insulated HF electrical cables from diffusing into the harness-protecting material. As a result, the insulated HF electrical cables are protected from the degradation of its anti-hot oxidizing quality.
[0544] In the wire harness of the invention, a cable bundle made of insulated HF-type electrical cables alone, or a mixture of them with insulated PVC-type electrical cables, is wrapped with a harness-protecting material of the invention. The electrical cables in the wire harness thus maintain a high anti-hot oxidizing quality, and secure a long and durable use.
[0545] Although the invention has been described with reference to particular means, materials and embodiments, it is to be understood that the invention is not limited to the particulars disclosed and extends to all equivalents within the scope of the claims.
[0546] The present disclosure relates to subject matter contained in priority Japanese Applications Nos. 2002-009367, 2002-009368 and 2002-009369, all filed on Jan. 18, 2002, which are all herein expressly incorporated by reference in their entireties.
TABLE 1 Composition of the cable coating for HF-type electrical cables content (parts by composition weight) polypropylene 100 magnesium hydroxide 80 anti-oxidizing agent (AA) 3 AA/100 parts by weight of base 3 organic material portion copper damage inhibitor 1 total (parts by weight) 184
[0547] [0547] TABLE 2 Composition of the cable coating for PVC-type electrical cables content (parts by composition weight) polyvinyl chloride (PVC) 100 polymerization rate 1300 diisononyl phthalate (DINP) 40 calcium carbonate 20 stabilizer 5 total (parts by weight) 165
[0548] [0548] TABLE 3 Composition of the cable coating for PVC-type electrical cables (containing an anti-oxidizingagent) composition content (parts by weight) polyvinyl chloride (PVC) 100 P: 1300 diisononyl phthalate 40 calcium carbonate 20 stabilizer 5 anti-oxidizing agent (AA) 4.5 AA/l00 parts by weight of base 3.2 organic material portion total (parts by weight) 169.5
[0549] [0549] TABLE 4 Common components and their manufacturers reagents manufacturer and trade marks polyvinyl chloride (PVC), P: 1300 Tosoh Co. Ltd.. polypropylene Idemitsu Petrochemicals “RB610A” polyolefin Sun Aroma Co. Ltd., “Q200F” styrene butadiene rubber (SBR) JSR Co. Ltd., “1013N” natural rubber (NR) RSS, “No.2” rosin type resin Arakawa Chemical Industries Co. Ltd., “Ester Gum H” hydrogenated terpene-type resin Yasuhara Chemicals Co. Ltd., “clearon P115” hydrogenated aromatic resin Arakawa Chemical Industries Co. Ltd., “Alcon P100” hydrogenated aliphatic resin Maruzen Petrochemicals Co. Ltd., “Marukarets H505” cumarone-indene type resin Morimura Sangyo “Kona cumarone #900” phenol type resin Gun-ei Chemical Industries Co. Ltd., “PS 2768” magnesium hydroxide (flame retardant) Kyowa Chemical Industries Co. Ltd., “Kisma 5” bromine-type flame retardant Teijin Chemicals Co. Ltd. “FG3100” antimony trioxide Chugoku Kogyo Co. Ltd. calcium carbonate (filler) Maruo Calcium Co. Ltd., “Super #1700” zinc white # 3 Sakai Chemical Industries Co. Ltd. stabilier Asahi Denka Industries Co. Ltd., “Rup 110” diisononyl phthalate (DINP) Daihachi Chemical Industries Co. Ltd. dioctyl phthalate (DOP) Daihachi Chemicals Industries Co. Ltd. anti-oxidizing agent Chiba Specialty Chemicals Co. Ltd., “Irganox 1010” copper damage inhibitor (for cable coatings) Asahi Denka Industries Co. Ltd., “CDA-1” copper damage inhibitor (for harness- Asahi Denka Industries Co. Ltd., “ZS27” protecting materials) carbon black Tokai Carbon Co. Ltd. “Seast SO” silica Nippon Silica Industries Co. Ltd. “Nipsil AQ” emulsion type acrylic acid resin Nippon Carbide Industries Co. Ltd. “L-145”
[0550] [0550] TABLE 5 Composition of PVC-type adhesive tapes (containing an anti-oxidizing agent) Tape base thickness : 0.11 mm: Adhesive thickness : 0.02 mm Prior Comparative Example Example Example Example Example Art 1 Example 1 1 2 3 4 5 composition of the tape base PVC(P: 1300) 100 100 100 100 100 100 100 DOP 60 60 60 60 60 60 60 calcium 20 20 20 20 20 20 20 carbonate stabilizer 5 5 5 5 5 5 5 anti-oxidizing — 30 0.5 5 7.5 12.5 25 agent (AA) AA/100 wt parts (−) (18.8) (0.3) (3.1) (4.7) (7.8) (15.6) of base org. mat. portion total (parts by 185 215 185.5 190 192.5 197.5 210 weight) composition of the adhesive SBR 70 70 70 70 70 70 70 natural rubber 30 30 30 30 30 30 30 zinc white # 3 20 20 20 20 20 20 20 rosin-type resin 80 — — — — — — hydrogenated — — 80 — — — — terpene-type resin Hydrogenated — — — 80 — — — aromatic resin hydrogenated — — — — 80 — — aliphatic resin cumarone-indene — — — — — 80 — type resin phenol-type resin — 80 — — — — 80 anti-oxidizing — 36 0.6 6 9 14 28 agent(AA) AA/100 wt parts (−) (20) (0.3) (3.3) (5) (7.8) (15.5) of base org. mat. portion total (parts by 200 236 200.6 206 209 214 228 weight)
[0551] [0551] TABLE 6 Composition of HF-type adhesive tapes (containing an anti-oxidizing agent) Tape base thickness : 0.11 mm: Adhesive thickness : 0.02 mm Prior Comparative Example Example Example Example Example Art 2 Example 2 6 7 8 9 10 composition of the tape base polyolefin 100 100 100 100 100 100 100 bromine-type 3 3 3 3 3 3 3 flame retardant antimony trioxide 1.5 1.5 1.5 1.5 1.5 1.5 1.5 anti-oxidizing — 20 0.4 3.5 5.5 8 16 agent (AA) AA/100 wt parts (−) (19.4) (0.4) (3.4) (5.3) (7.8) (15.5) of base org. mat. portion total (parts by 104.5 124.5 104.9 108 110 112.5 120.5 weight) composition of the adhesive SBR 70 70 70 70 70 70 70 natural rubber 30 30 30 30 30 30 30 zinc white # 3 20 20 20 20 20 20 20 rosin-type resin 80 — — — — — — hydrogenated — — 80 — — — — terpene-type resin hydrogenated — — — 80 — — — aromatic resin hydrogenated — — — — 80 — — aliphatic resin coumarone- — — — — — 80 — indene type resin phenol-type resin — 80 — — — — 80 anti-oxidizing — 36 0.6 6 9 14 28 agent (AA) AA/100 wt parts (−) (20) (0.3) (3.3) (5) (7.8) (15.5) of base org. mat. portion total (parts by 200 236 200.6 206 209 214 228 weight)
[0552] [0552] TABLE 7 Composition of PVC-type adhesive tapes (containing a copper damage inhibitor) Tape base thickness : 0.11 mm: Adhesive thickness : 0.02 mm Prior Comparative Example Example Example Example Example Art 3 Example 3 11 12 13 14 15 composition of the tape base PVC(P: 1300) 100 100 100 100 100 100 100 DOP 60 60 60 60 60 60 60 calcium 20 20 20 20 20 20 20 carbonate stabilizer 5 5 5 5 5 5 5 copper damage — 11.2 0.002 0.016 1.6 4.8 8 inhibitor total (parts by 185 196.2 185.002 185.016 186.6 189.8 193 weight) composition of the adhesive SBR 70 70 70 70 70 70 70 natural rubber 30 30 30 30 30 30 30 zinc white # 3 20 20 20 20 20 20 20 rosin-type resin 80 — — — — — — hydrogenated — — 80 — — — — terpene-type resin hydrogenated — — — 80 — — — aromatic resin hydrogenated — — — — 80 — — aliphatic resin coumarone- — — — — — 80 — indene type resin phenol-type resin — 80 — — — — 80 copper damage — 12.6 0.002 0.02 1.8 4.8 9 inhibitor total (parts by 200 212.6 200.002 200.02 201.8 204.8 209 weight)
[0553] [0553] TABLE 8 Composition of HF-type adhesive tapes (containing a copper damage inhibitor) Tape base thickness : 0.11 mm: Adhesive thickness : 0.02 mm Prior Comparative Example Example Example Example Example Art 4 Example 4 16 17 18 19 20 composition of the tape base polyolefin 100 100 100 100 100 100 100 bromine-type 3 3 3 3 3 3 3 flame retardant antimony trioxide 1.5 1.5 1.5 1.5 1.5 1.5 1.5 copper damage- — 7.2 0.001 0.01 1 3.1 5.2 preventing agent total (parts by 104.5 111.7 104.501 104.51 105.5 107.6 109.7 weight) composition of the adhesive SBR 70 70 70 70 70 70 70 natural rubber 30 30 30 30 30 30 30 zinc white # 3 20 20 20 20 20 20 20 rosin-type resin 80 — — — — — — hydrogenated — — 80 — — — — terpene-type resin hydrogenated — — — 80 — — — aromatic resin hydrogenated — — — — 80 — — aliphatic resin coumarone- — — — — — 80 — indene type resin phenol-type resin — 80 — — — — 80 copper damage — 12.6 0.002 0.02 1.8 4.8 9 inhibitor total (parts by 200 212.6 200.002 200.02 201.8 204.8 209 weight)
[0554] [0554] TABLE 9 Composition of PVC-type adhesive tapes (containing an anti-oxidizing agent and a copper damage inhibitor) Tape base thickness : 0.11 mm: Adhesive thickness : 0.02 mm Prior Comparative Example Example Example Example Example Art 5 Example 5 21 22 23 24 25 composition of the tape base PVC(P: 1300) 100 100 100 100 100 100 100 DOP 60 60 60 60 60 60 60 calcium 20 20 20 20 20 20 20 carbonate stabilizer 5 5 5 5 5 5 5 anti-oxidizing — 5 5 5 5 5 5 agent (AA) AA/100 wt parts (−) (3.1) (3.1) (3.1) (3.1) (3.1) (3.1) of base org. mat. portion copper damage — 11.2 0.002 0.016 1.6 4.8 8 inhibitor total (parts by 185 201.2 190.002 190.016 191.6 194.8 198 weight) composition of the adhesive SBR 70 70 70 70 70 70 70 natural rubber 30 30 30 30 30 30 30 zinc white # 3 20 20 20 20 20 20 20 rosin-type resin 80 — — — — — — hydrogenated — — 80 — — — — terpene-type resin aromatic-type — — — 80 — — — hydrolysed resin hydrogenated — — — — 80 — — aliphatic resin coumarone- — — — — — 80 — indene type resin phenol-type resin — 80 — — — — 80 anti-oxidizing — 6 6 6 6 6 6 agent (AA) AA/100 wt parts (−) (3.3) (3.3) (3.3) (3.3) (3.3) (3.3) of base org. mat. portion copper damage — 12.6 0.002 0.02 1.8 4.8 9 inhibitor total (parts by 200 218.6 206.002 206.02 207.8 210.8 215 weight)
[0555] [0555] TABLE 10 Composition of HF-type adhesive tapes (containing a copper damage inhibitor) Tape base thickness : 0.11 mm: Adhesive thickness : 0.02 mm Prior Comparative Example Example Example Example Example Art 6 Example 6 26 27 28 29 30 composition of the tape base polyolefin 100 100 100 100 100 100 100 bromine-type 3 3 3 3 3 3 3 flame retardant antimony trioxide 1.5 1.5 1.5 1.5 1.5 1.5 1.5 anti-oxidizing — 3.5 3.5 3.5 3.5 3.5 3.5 agent (AA) AA/100 wt parts (−) (3.4) (3.4) (3.4) (3.4) (3.4) (3.4) of base org. mat. portion copper damage — 7.2 0.001 0.01 1 3.1 5.2 inhibitor total (parts by 104.5 115.2 108.001 108.01 109 111.1 113.2 weight) composition of the adhesive SBR 70 70 70 70 70 70 70 natural rubber 30 30 30 30 30 30 30 zinc white # 3 20 20 20 20 20 20 20 rosin-type resin 80 — — — — — — hydrogenated — — 80 — — — — terpene-type resin hydrogenated — — — 80 — — — aromatic resin hydrogenated — — — — 80 — — aliphatic resin coumarone- — — — — — 80 — indene type resin phenol-type resin — 80 — — — — 80 anti-oxidizing — 6 6 6 6 6 6 agent (AA) AA/100 wt parts (−) (3.3) (3.3) (3.3) (3.3) (3.3) (3.3) of basse org. mat. portion copper damage — 12.6 0.002 0.02 1.8 4.8 9 inhibitor total (parts by 200 218.6 206.002 206.02 207.8 210.8 215 weight)
[0556] [0556] TABLE 11 HF-type plain cable bundle × PVC-type adhesive tape (containing an anti-oxidizing agent) type of wire harness Comparative Prior Example Example Example Example Example Example Art W1 W1 W1 W2 W3 W4 W5 HF-type plain cable bundle (30 electrical cables) cable bundle Prior Comparative Example Example Example Example Example type of Art 1 Example 1 1 2 3 4 5 adhesive tape experimental results 150° C., 96 hr, X ◯ ◯ ◯ ◯ ◯ ◯ 10φ mandrel- (cable) (cable) (cable) (cable) (cable) (cable) (cable) winding wrapping ◯ X ◯ ◯ ◯ ◯ ◯ operation gluing ◯ X ◯ ◯ ◯ ◯ ◯ capacity global X X ◯ ◯ ◯ ◯ ◯ evaluation
[0557] [0557] TABLE 12 HF-type plain cable bundle × HF-type adhesive tape (containing an anti-oxidizing agent) type of wire harness Comparative Prior Example Example Example Example Example Example Art W2 W2 W6 W7 W8 W9 W10 HF-type plain cable bundle (30 electrical cables) cable bundle Prior Comparative Example Example Example Example Example type of Art 2 Example 2 6 7 8 9 10 adhesive tape experimental results 150° C., 96 hr, X ◯ ◯ ◯ ◯ ◯ ◯ 10φ mandrel- (cable) (cable) (cable) (cable) (cable) (cable) (cable) winding X ◯ ◯ ◯ ◯ ◯ ◯ (tape) (tape) (tape) (tape) (tape) (tape) (tape) wrapping ◯ X ◯ ◯ ◯ ◯ ◯ operation gluing ◯ X ◯ ◯ ◯ ◯ ◯ capacity global X X ◯ ◯ ◯ ◯ ◯ evaluation
[0558] [0558] TABLE 13 HF-type plain cable bundle × PVC-type adhesive tape (containing a copper damage inhibitor) type of wire harness Comparative Prior Example Example Example Example Example Example Art W3 W3 W11 W12 W13 W14 W15 HF-type plain cable bundle (30 electrical cables) cable bundle Prior Comparative Example Example Example Example Example type of Art 3 Example 3 11 12 13 14 15 adhesive tape experimental results 150° C., 96 hr, X ◯ ◯ ◯ ◯ ◯ ◯ 10φ mandrel- (cable) (cable) (cable) (cable) (cable) (cable) (cable) winding wrapping ◯ X ◯ ◯ ◯ ◯ ◯ operation appearance ◯ X ◯ ◯ ◯ ◯ ◯ gluing ◯ X ◯ ◯ ◯ ◯ ◯ capacity global X X ◯ ◯ ◯ ◯ ◯ evaluation
[0559] [0559] TABLE 14 HF-type plain cable bundle × HF-type adhesive tape (containing a copper damage inhibitor) type of wire harness Comparative Prior Example Example Example Example Example Example Art W4 W4 W16 W17 W18 W19 W20 HF-type plain cable bundle (30 electrical cables) cable bundle Prior Comparative Example Example Example Example Example type of Art 4 Example 4 16 17 18 19 20 adhesive tape experimental results 150° C., 96 hr, X ◯ ◯ ◯ ◯ ◯ ◯ 10φ mandrel- (cable) (cable) (cable) (cable) (cable) (cable) (cable) winding X ◯ ◯ ◯ ◯ ◯ ◯ (tape) (tape) (tape) (tape) (tape) (tape) (tape) wrapping ◯ X ◯ ◯ ◯ ◯ ◯ operation appearance ◯ X ◯ ◯ ◯ ◯ ◯ gluing ◯ X ◯ ◯ ◯ ◯ ◯ capacity global X X ◯ ◯ ◯ ◯ ◯ evaluation
[0560] [0560] TABLE 15 HF-type plain cable bundle × PVC-type adhesive tape (containing an anti-oxidizing agent and a copper damage inhibitor) type of wire harness Comparative Prior Example Example Example Example Example Example Art W5 W5 W21 W22 W23 W24 W25 HF-type plain cable bundle (30 electrical cables) cable bundle Prior Comparative Example Example Example Example Example type of Art 5 Example 5 21 22 23 24 25 adhesive tape experimental results 150° C., 96 hr, X ◯ ◯ ◯ ◯ ◯ ◯ 10φ mandrel- (cable) (cable) (cable) (cable) (cable) (cable) (cable) winding wrapping ◯ X ◯ ◯ ◯ ◯ ◯ operation appearance ◯ X ◯ ◯ ◯ ◯ ◯ gluing ◯ X ◯ ◯ ◯ ◯ ◯ capacity global X X ◯ ◯ ◯ ◯ ◯ evaluation
[0561] [0561] TABLE 16 HF-type plain cable bundle × HF-type adhesive tape (containing an anti-oxidizing agent and a copper damage inhibitor) type of wire harness Comparative Prior Example Example Example Example Example Example Art W6 W6 W26 W27 W28 W29 W30 HF-type plain cable bundle (30 electrical cables) cable bundle Prior Comparative Example Example Example Example Example type of Art 6 Example 6 26 27 28 29 30 adhesive tape experimental results 150° C., 96 hr, X ◯ ◯ ◯ ◯ ◯ ◯ 10φ mandrel- (cable) (cable) (cable) (cable) (cable) (cable) (cable) winding X ◯ ◯ ◯ ◯ ◯ ◯ (tape) (tape) (tape) (tape) (tape) (tape) (tape) wrapping ◯ X ◯ ◯ ◯ ◯ ◯ operation appearance ◯ X ◯ ◯ ◯ ◯ ◯ gluing ◯ X ◯ ◯ ◯ ◯ ◯ capacity global X X ◯ ◯ ◯ ◯ ◯ evaluation
[0562] [0562] TABLE 17 (Mixed cable bundle of PVC-type electrical cables and HF-type electrical cables) × PVC-type adhesive tape (containing an anti-oxidizing agent) type of wire harness Comparative Prior Art Example Example Example Example Example Example W7 W7 W31 W32 W33 W34 W35 number ratio of PVC-type cables:HF-type cables 20: 1: 29: 20: 1: 29:1 20:10 1:29 29:1 20:10 1:29 29:1 20:10 1:29 29:1 20:10 1:29 29:1 20:10 1:29 29:1 10 29 1 10 29 type of adhesive tape Prior Art Comparative Example Example Example Example Example 1 Example 1 1 2 3 4 5 experimental results 150° C., X ◯ ◯ ◯ ◯ ◯ ◯ 96 hr, 10φ (cable) (cable) (cable) (cable) (cable) (cable) (cable) mandrel- winding wrapping ◯ X ◯ ◯ ◯ ◯ ◯ operation gluing ◯ X ◯ ◯ ◯ ◯ ◯ capacity global X X ◯ ◯ ◯ ◯ ◯ evaluation
[0563] [0563] TABLE 18 (Mixed cable bundle of PVC-type electrical cables and HF-type electrical cables) × HF-type adhesive tape (containing an anti-oxidizing agent) type of wire harness Comparative Prior Art Example Example Example Example Example Example W8 W8 W36 W37 W38 W39 W40 number ratio of PVC-type cables:HF-type cables 20: 1: 29: 20: 1: 29:1 20:10 1:29 29:1 20:10 1:29 29:1 20:10 1:29 29:1 20:10 1:29 29:1 20:10 1:29 29:1 10 29 1 10 29 type of adhesive tape Prior Art Comparative Example Example Example Example Example 2 Example 2 6 7 8 9 10 experimental results 150° C., X ◯ ◯ ◯ ◯ ◯ ◯ 96 hr, 10φ (cable) (cable) (cable) (cable) (cable) (cable) (cable) mandrel- X ◯ ◯ ◯ ◯ ◯ ◯ winding (tape) (tape) (tape) (tape) (tape) (tape) (tape) wrapping ◯ X ◯ ◯ ◯ ◯ ◯ operation gluing ◯ X ◯ ◯ ◯ ◯ ◯ capacity global X X ◯ ◯ ◯ ◯ ◯ evaluation
[0564] [0564] TABLE 19 (Mixed cable bundle of PVC-type electrical cables and HF-type electrical cables) × PVC-type adhesive tape (containing a copper damage inhibitor) type of wire harness Comparative Prior Art Example Example Example Example Example Example W9 W9 W41 W42 W43 W44 W45 number ratio of PVC-type cables:HF-type cables 20: 1: 29: 20: 1: 29:1 20:10 1:29 29:1 20:10 1:29 29:1 20:10 1:29 29:1 20:10 1:29 29:1 20:10 1:29 29:1 10 29 1 10 29 type of adhesive tape Prior Art Comparative Example Example Example Example Example 3 Example 3 11 12 13 14 15 experimental results 150° C., X ◯ ◯ ◯ ◯ ◯ ◯ 96 hr, 10φ (cable) (cable) (cable) (cable) (cable) (cable) (cable) mandrel- winding wrapping ◯ X ◯ ◯ ◯ ◯ ◯ operation appear- ◯ X ◯ ◯ ◯ ◯ ◯ ance gluing ◯ X ◯ ◯ ◯ ◯ ◯ capacity global X X ◯ ◯ ◯ ◯ ◯ evaluation
[0565] [0565] TABLE 20 (Mixed cable bundle of PVC-type electrical cables and HF-type electrical cables) × HF-type adhesive tape (containing a copper damage inhibitor) type of wire harness Comparative Prior Art Example Example Example Example Example Example W10 W10 W46 W47 W48 W49 W50 number ratio of PVC-type cables:HF-type cables 20: 1: 29: 20: 1: 29:1 20:10 1:29 29:1 20:10 1:29 29:1 20:10 1:29 29:1 20:10 1:29 29:1 20:10 1:29 29:1 10 29 1 10 29 type of adhesive tape Prior Art Comparative Example Example Example Example Example 4 Example 4 16 17 18 19 20 experimental results 150° C., X ◯ ◯ ◯ ◯ ◯ ◯ 96 hr, 10φ (cable) (cable) (cable) (cable) (cable) (cable) (cable) mandrel- X ◯ ◯ ◯ ◯ ◯ ◯ winding (tape) (tape) (tape) (tape) (tape) (tape) (tape) wrapping ◯ X ◯ ◯ ◯ ◯ ◯ operation appear- ◯ X ◯ ◯ ◯ ◯ ◯ ance gluing ◯ X ◯ ◯ ◯ ◯ ◯ capacity global X X ◯ ◯ ◯ ◯ ◯ evaluation
[0566] [0566] TABLE 21 (Mixed cable bundle of PVC-type electrical cables and HF-type electrical cables) × PVC-type adhesive tape (containing an anti-oxidizing agent and a copper type of wire harness Comparative Prior Art Example Example Example Example Example Example W11 W11 W51 W52 W53 W54 W55 number ratio of PVC-type cables:HF-type cables 20: 1: 29: 20: 1: 29:1 20:10 1:29 29:1 20:10 1:29 29:1 20:10 1:29 29:1 20:10 1:29 29:1 20:10 1:29 29:1 10 29 1 10 29 type of adhesive tape Prior Art Comparative Example Example Example Example Example 5 Example 5 21 22 23 24 25 experimental results 150° C., X ◯ ◯ ◯ ◯ ◯ ◯ 96 hr, 10φ (cable) (cable) (cable) (cable) (cable) (cable) (cable) mandrel- winding wrapping ◯ X ◯ ◯ ◯ ◯ ◯ operation appear- ◯ X ◯ ◯ ◯ ◯ ◯ ance gluing ◯ X ◯ ◯ ◯ ◯ ◯ capacity global X X ◯ ◯ ◯ ◯ ◯ evaluation
[0567] [0567] TABLE 22 (Mixed cable bundle of PVC-type electrical cables and HF-type electrical cables) × HF-type adhesive tape (containing an anti-oxidizing agent and a copper damage inhibitor) type of wire harness Comparative Prior Art Example Example Example Example Example Example W12 W12 W56 W57 W58 W59 W60 number ratio of PVC-type cables:HF-type cables 20: 1: 29: 20: 1: 29:1 20:10 1:29 29:1 20:10 1:29 29:1 20:10 1:29 29:1 20:10 1:29 29:1 20:10 1:29 29:1 10 29 1 10 29 type of adhesive tape Prior Art Comparative Example Example Example Example Example 6 Example 6 26 27 28 29 30 experimental results 150° C., X ◯ ◯ ◯ ◯ ◯ ◯ 96 hr, 10φ (cable) (cable) (cable) (cable) (cable) (cable) (cable) mandrel- X ◯ ◯ ◯ ◯ ◯ ◯ winding (tape) (tape) (tape) (tape) (tape) (tape) (tape) wrapping ◯ X ◯ ◯ ◯ ◯ ◯ operation appear- ◯ X ◯ ◯ ◯ ◯ ◯ ance gluing ◯ X ◯ ◯ ◯ ◯ ◯ capacity global X X ◯ ◯ ◯ ◯ ◯ evaluation
[0568] [0568] TABLE 23 [Mixed cable bundle of PVC-type electrical cables (containing an anti-oxidizing agent) and HF-type electrical cables] × PVC-type adhesive tape (containing an anti-oxidizing agent) type of wire harness Comparative Prior Art Example Example Example Example Example Example W13 W13 W61 W62 W63 W64 W65 number ratio of PVC-type cables (containing an anti-oxidizing agent):HF-type cables 20: 1: 29: 20: 1: 29:1 20:10 1:29 29:1 20:10 1:29 29:1 20:10 1:29 29:1 20:10 1:29 29:1 20:10 1:29 29:1 10 29 1 10 29 type of adhesive tape Prior Art Comparative Example Example Example Example Example 1 Example 1 1 2 3 4 5 experimental results 150° C., X ◯ ◯ ◯ ◯ ◯ ◯ 96 hr, 10φ (cable) (cable) (cable) (cable) (cable) (cable) (cable) mandrel- winding wrapping ◯ X ◯ ◯ ◯ ◯ ◯ operation gluing ◯ X ◯ ◯ ◯ ◯ ◯ capacity global X X ◯ ◯ ◯ ◯ ◯ evaluation
[0569] [0569] TABLE 24 [Mixed cable bundle of PVC-type electrical cables (containing an anti-oxidizing agent) and HF-type electrical cables] × HF-type adhesive type (containing an anti-oxidizing agent) type of wire harness Comparative Prior Art Example Example Example Example Example Example W14 W14 W66 W67 W68 W69 W70 number ratio of PVC-type cables (containing an anti-oxidizing agent):HF-type cables 20: 1: 29: 20: 1: 29:1 20:10 1:29 29:1 20:10 1:29 29:1 20:10 1:29 29:1 20:10 1:29 29:1 20:10 1:29 29:1 10 29 1 10 29 type of adhesive tape Prior Art Comparative Example Example Example Example Example 2 Example 2 6 7 8 9 10 experimental results 150° C., X ◯ ◯ ◯ ◯ ◯ ◯ 96 hr, 10φ (cable) (cable) (cable) (cable) (cable) (cable) (cable) mandrel- X ◯ ◯ ◯ ◯ ◯ ◯ winding (tape) (tape) (tape) (tape) (tape) (tape) (tape) wrapping ◯ X ◯ ◯ ◯ ◯ ◯ operation gluing ◯ X ◯ ◯ ◯ ◯ ◯ capacity global X X ◯ ◯ ◯ ◯ ◯ evaluation
[0570] [0570] TABLE 25 [Mixed cable bundle of PVC-type electrical cables (containing an anti-oxidizing agent) and HF-type electrical cables] × PVC-type adhesive tape (containing a copper damage inhibitor) type of wire harness Comparative Prior Art Example Example Example Example Example Example W15 W15 W71 W72 W73 W74 W75 number ratio of PVC-type cables (containing an anti-oxidizing agent):HF-type cables 20: 1: 29: 20: 1: 29:1 20:10 1:29 29:1 20:10 1:29 29:1 20:10 1:29 29:1 20:10 1:29 29:1 20:10 1:29 29:1 10 29 1 10 29 type of adhesive tape Prior Art Comparative Example Example Example Example Example 3 Example 3 11 12 13 14 15 experimental results 150° C., X ◯ ◯ ◯ ◯ ◯ ◯ 96 hr, 10φ mandrel- (cable) (cable) (cable) (cable) (cable) (cable) (cable) winding wrapping ◯ X ◯ ◯ ◯ ◯ ◯ operation appear- ◯ X ◯ ◯ ◯ ◯ ◯ ance gluing ◯ X ◯ ◯ ◯ ◯ ◯ capacity global X X ◯ ◯ ◯ ◯ ◯ evaluation
[0571] [0571] TABLE 26 [Mixed cable bundle of PVC-type electrical cables (containing an anti-oxidizing agent) and HF-type electrical cables] × HF-type adhesive tape (containing a copper damage inhibitor) type of wire harness Comparative Prior Art Example Example Example Example Example Example W16 W16 W76 W77 W78 W79 W80 number ratio of PVC-type cables (containing an anti-oxidizing agent):HF-type cables 20: 1: 29: 20: 1: 29:1 20:10 1:29 29:1 20:10 1:29 29:1 20:10 1:29 29:1 20:10 1:29 29:1 20:10 1:29 29:1 10 29 1 10 29 type of adhesive tape Prior Art Comparative Example Example Example Example Example 4 Example 4 16 17 18 19 20 experimental results 150° C., X ◯ ◯ ◯ ◯ ◯ ◯ 96 hr, 10φ (cable) (cable) (cable) (cable) (cable) (cable) (cable) mandrel- X ◯ ◯ ◯ ◯ ◯ ◯ winding (tape) (tape) (tape) (tape) (tape) (tape) (tape) wrapping ◯ X ◯ ◯ ◯ ◯ ◯ operation appear- ◯ X ◯ ◯ ◯ ◯ ◯ ance gluing ◯ X ◯ ◯ ◯ ◯ ◯ capacity global X X ◯ ◯ ◯ ◯ ◯ evaluation
[0572] [0572] TABLE 27 [Mixed cable bundle of PVC-type electrical cables (containing an anti-oxidizing agent) and HF-type electrical cables] × PVC-type adhesive tape (containing a copper damage inhibitor) type of wire harness Comparative Prior Art Example Example Example Example Example Example W17 W17 W81 W82 W83 W84 W85 number ratio of PVC-type cables (containing an anti-oxidizing agent):HF-type cables 20: 1: 29: 20: 1: 29:1 20:10 1:29 29:1 20:10 1:29 29:1 20:10 1:29 29:1 20:10 1:29 29:1 20:10 1:29 29:1 10 29 1 10 29 type of adhesive tape Prior Art Comparative Example Example Example Example Example 5 Example 5 21 22 23 24 25 experimental results 150° C., X ◯ ◯ ◯ ◯ ◯ ◯ 96 hr, 10φ (cable) (cable) (cable) (cable) (cable) (cable) (cable) mandrel- winding wrapping ◯ X ◯ ◯ ◯ ◯ ◯ operation appear- ◯ X ◯ ◯ ◯ ◯ ◯ ance gluing ◯ X ◯ ◯ ◯ ◯ ◯ capacity global X X ◯ ◯ ◯ ◯ ◯ evaluation
[0573] [0573] TABLE 28 [Mixed cable bundle of PVC-type electrical cables (containing an anti-oxidizing agent) and HF-type electrical cables] × HF-type adhesive tape (containing an anti-oxidizing agent and a copper damage inhibitor) type of wire harness Comparative Prior Art Example Example Example Example Example Example W18 W18 W86 W87 W88 W89 W90 number ratio of PVC-type cables (containing an anti-oxidizing agent):HF-type cables 20: 1: 29: 20: 1: 29:1 20:10 1:29 29:1 20:10 1:29 29:1 20:10 1:29 29:1 20:10 1:29 29:1 20:10 1:29 29:1 10 29 1 10 29 type of adhesive tape Prior Art Comparative Example Example Example Example Example 6 Example 6 26 27 28 29 30 experimental results 150° C., X ◯ ◯ ◯ ◯ ◯ ◯ 96 hr, 10φ (cable) (cable) (cable) (cable) (cable) (cable) (cable) mandrel- X ◯ ◯ ◯ ◯ ◯ ◯ winding (tape) (tape) (tape) (tape) (tape) (tape) (tape) wrapping ◯ X ◯ ◯ ◯ ◯ ◯ operation appear- ◯ X ◯ ◯ ◯ ◯ ◯ ance gluing ◯ X ◯ ◯ ◯ ◯ ◯ capacity global X X ◯ ◯ ◯ ◯ ◯ evaluation
[0574] [0574] TABLE 29 Composition of PVC-type adhesive tapes (containing an anti-oxidizing agent) Tape base thickness: 0.11 mm: Adhesive thickness: 0.02 mm Prior composition Art 1 C. E. 1 C. E. 2 E. 1 E. 2 E. 3 E. 4 E. 5 E. 6 tape base PVC (P: 1300) 100 100 100 100 100 100 100 100 100 DOP 60 60 60 60 60 60 60 60 60 calcium 20 20 20 20 20 20 20 20 20 carbonate stabilizer 5 5 5 5 5 5 5 5 5 anti-oxidizing — 5 5 5 5 5 5 5 5 agent (AA) AA/100 wt (−) (3.1) (3.1) (3.1) (3.1) (3.1) (3.1) (3.1) (3.1) parts of base org. mat. portion carbon black — 160 — 1 10 150 — — — silica — — 160 — — — 1 10 150 total (parts by 185 350 350 191 200 340 191 200 340 weight) adhesive SBR 70 70 70 70 70 70 70 70 70 natural rubber 30 30 30 30 30 30 30 30 30 zinc white # 3 20 20 20 20 20 20 20 20 20 rosin-type resin 80 — — — — — — — — hydrogenated — 80 80 80 80 80 80 80 80 aromatic resin anti-oxidizing — 6 6 6 6 6 6 6 6 agent (AA) AA/100 wt parts (−) (3.3) (3.3) (3.3) (3.3) (3.3) (3.3) (3.3) (3.3) of base org. mat. portion carbon black — 160 — 1 10 150 — — — silica — — 160 — — — 1 10 150 total (parts by 200 366 366 207 216 356 207 216 356 weight)
[0575] [0575] TABLE 30 Composition of HF-type adhesive tapes (containing an anti-oxidizing agent) Tape base thickness: 0.11 mm: Adhesive thickness: 0.02 mm Prior composition Art 2 C. E. 3 C. E. 4 E. 7 E. 8 E. 9 E. 10 E. 11 E. 12 tape base polyolefin 100 100 100 100 100 100 100 100 100 bromine-type 3 3 3 3 3 3 3 3 3 flame retardant antimony trioxide 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 anti-oxidizing — 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 agent (AA) AA/100 wt parts (−) (3.4) (3.4) (3.4) (3.4) (3.4) (3.4) (3.4) (3.4) of base org. mat. portion carbon black — 160 — 1 10 150 — — — silica — — 160 — — — 1 10 150 total (parts by 104.5 268 268 109 118 258 109 118 258 weight) adhesive SBR 70 70 70 70 70 70 70 70 70 natural rubber 30 30 30 30 30 30 30 30 30 zinc white # 3 20 20 20 20 20 20 20 20 20 rosin-type resin 80 — — — — — — — — hydrogenated — 80 80 80 80 80 80 80 80 aromatic resin anti-oxidizing — 6 6 6 6 6 6 6 6 agent (AA) AA/100 wt parts (−) (3.3) (3.3) (3.3) (3.3) (3.3) (3.3) (3.3) (3.3) of base org. mat. portion carbon black — 160 — 1 10 150 — — — silica — — 160 — — — 1 10 150 total (parts by 200 366 366 207 216 356 207 216 356 weight)
[0576] [0576] TABLE 31 Composition of PVC-type adhesive tapes (containing a copper damage inhibitor) Tape base thickness: 0.11 mm: Adhesive thickness: 0.02 mm Prior composition Art 3 C. E. 5 C. E. 6 E. 13 E. 14 E. 15 E. 16 E. 17 E. 18 tape base PVC (P: 1300) 100 100 100 100 100 100 100 100 100 DOP 60 60 60 60 60 60 60 60 60 calcium 20 20 20 20 20 20 20 20 20 carbonate stabilizer 5 5 5 5 5 5 5 5 5 copper damage — 1.6 1.6 1.6 1.6 1.6 1.6 1.6 1.6 inhibitor carbon black — 160 — 1 10 150 — — — silica — — 160 — — — 1 10 150 total (parts by 185 346.6 346.6 187.6 196.6 336.6 187.6 196.6 336.6 weight) adhesive SBR 70 70 70 70 70 70 70 70 70 natural rubber 30 30 30 30 30 30 30 30 30 zinc white # 3 20 20 20 20 20 20 20 20 20 rosin-type resin 80 — — — — — — — — hydrogenated — 80 80 80 80 80 80 80 80 aromatic resin copper damage — 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 inhibitor carbon black — 160 — 1 10 150 — — — silica — — 160 — — — 1 10 150 total 200 361.8 361.8 202.8 211.8 351.8 202.8 211.8 351.8 (parts by weight)
[0577] [0577] TABLE 32 Composition of HF-type adhesive tapes (containing a copper damage inhibitor) Tape base thickness: 0.11 mm: Adhesive thickness: 0.02 mm Prior composition Art 4 C. E. 7 C. E. 8 E. 19 E. 20 E. 21 E. 22 E. 23 E. 24 tape base polyolefin 100 100 100 100 100 100 100 100 100 bromine-type 3 3 3 3 3 3 3 3 3 flame retardant antimony 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 trioxide copper damage — 1 1 1 1 1 1 1 1 inhibitor carbon black — 160 — 1 10 150 — — — silica — — 160 — — — 1 10 150 total (parts by 104.5 265.5 265.5 106.5 115.5 255.5 106.5 115.5 255.5 weight) adhesive SBR 70 70 70 70 70 70 70 70 70 natural rubber 30 30 30 30 30 30 30 30 30 zinc white # 3 20 20 20 20 20 20 20 20 20 rosin-type resin 80 — — — — — — — — hydrogenated — 80 80 80 80 80 80 80 80 aromatic resin copper damage — 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 inhibitor carbon black — 160 — 1 10 150 — — — silica — — 160 — — — 1 10 150 total 200 361 361 202.8 211.8 351.8 202.8 211.8 351.8 (parts by weight)
[0578] [0578] TABLE 33 Composition of PVC-type adhesive tapes (containing an anti-oxidizing agent and a copper damage inhibitor) Tape base thickness: 0.11 mm: Adhesive thickness: 0.02 mm Prior composition Art 5 C. E. 9 C. E. 10 E. 25 E. 26 E. 27 E. 28 E. 29 E. 30 tape base PVC (P: 1300) 100 100 100 100 100 100 100 100 100 DOP 60 60 60 60 60 60 60 60 60 calcium carbonate 20 20 20 20 20 20 20 20 20 stabilizer 5 5 5 5 5 5 5 5 5 anti-oxidizing — 5 5 5 5 5 5 5 5 agent (AA) AA/100 wt parts (−) (3.1) (3.1) (3.1) (3.1) (3.1) (3.1) (3.1) (3.1) of base org. mat. portion copper damage — 1.6 1.6 1.6 1.6 1.6 1.6 1.6 1.6 inhibitor carbon black — 160 — 1 10 150 — — — silica — — 160 — — — 1 10 150 total (parts by 185 351.6 351.6 192.6 201.6 341.6 192.6 201.6 341.6 weight) adhesive SBR 70 70 70 70 70 70 70 70 70 natural rubber 30 30 30 30 30 30 30 30 30 zinc white # 3 20 20 20 20 20 20 20 20 20 rosin-type resin 80 — — — — — — — — hydrogenated — 80 80 80 80 80 80 80 80 aromatic resin anti-oxidizing — 6 6 6 6 6 6 6 6 agent (AA) AA/100 wt parts (−) (3.3) (3.3) (3.3) (3.3) (3.3) (3.3) (3.3) (3.3) of base org. mat. portion copper damage — 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 inhibitor carbon black — 160 — 1 10 150 — — — silica — — 160 — — — 1 10 150 total (parts by 200 367.8 367.8 208.8 217.8 357.8 208.8 217.8 357.8 weight)
[0579] [0579] TABLE 34 Composition of HF-type adhesive tapes (containing an anti-oxidizing agent and a copper damage inhibitor) Tape base thickness: 0.11 mm: Adhesive thickness: 0.02 mm Prior composition Art 6 C. E. 11 C. E. 12 E. 31 E. 32 E. 33 E. 34 E. 35 E. 36 tape base polyolefin 100 100 100 100 100 100 100 100 100 bromine-type 3 3 3 3 3 3 3 3 3 flame retardant antimony trioxide 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 anti-oxidizing — 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 agent (AA) AA/100 wt parts (−) (3.4) (3.4) (3.4) (3.4) (3.4) (3.4) (3.4) (3.4) of base org. mat. portion copper damage — 1 1 1 1 1 1 1 1 inhibitor carbon black — 160 — 1 10 150 — — — silica — — 160 — — — 1 10 150 total (parts by 104.5 269 269 110 119 259 110 119 259 weight) adhesive SBR 70 70 70 70 70 70 70 70 70 natural rubber 30 30 30 30 30 30 30 30 30 zinc white # 3 20 20 20 20 20 20 20 20 20 rosin-type resin 80 — — — — — — — — hydrogenated — 80 80 80 80 80 80 80 80 aromatic resin anti-oxidizing — 6 6 6 6 6 6 6 6 agent (AA) AA/100 wt parts (−) (3.3) (3.3) (3.3) (3.3) (3.3) (3.3) (3.3) (3.3) of base org. mat. portion copper damage — 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 inhibitor carbon black — 160 — 1 10 150 — — — silica — — 160 — — — 1 10 150 total (parts by 200 367.8 367.8 208.8 217.8 357.8 208.8 217.8 357.8 weight)
[0580] [0580] TABLE 35 HF-type plain cable bundle × PVC-type adhesive tape (containing an anti-oxidizing agent) type of wire harness Prior C. E. C. E. Art W1 W1 W2 E. W1 E. W2 E. W3 E. W4 E. W5 E. W6 HF-type plain cable bundle (30 electrical cables) type of Prior adhesive Art 1 C. E. 1 C. E. 2 E. 1 E. 2 E. 3 E. 4 E. 5 E. 6 tape experimental results 150° C., X ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ 96 hr, 10φ (cable) (cable) (cable) (cable) (cable) (cable) (cable) (cable) (cable) mandrel- winding wrapping ◯ X X ◯ ◯ ◯ ◯ ◯ ◯ operation gluing ◯ X X ◯ ◯ ◯ ◯ ◯ ◯ capacity global X X X ◯ ◯ ◯ ◯ ◯ ◯ evaluation
[0581] [0581] TABLE 36 HF-type plain cable bundle × HF-type adhesive tape (containing an anti-oxidizing agent) type of wire harness Prior C. E. C. E. Art W2 W3 W4 E. W7 E. W8 E. W9 E. W10 E. W11 E. W12 HF-type plain cable bundle (30 electrical cables) type of Prior adhesive Art 2 C. E. 3 C. E. 4 E. 7 E. 8 E. 9 E. 10 E. 11 E. 12 tape experimental results 150° C., X ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ 96 hr, 10φ (cable) (cable) (cable) (cable) (cable) (cable) (cable) (cable) (cable) mandrel- X ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ winding (tape) (tape) (tape) (tape) (tape) (tape) (tape) (tape) (tape) wrapping ◯ X X ◯ ◯ ◯ ◯ ◯ ◯ operation gluing ◯ X X ◯ ◯ ◯ ◯ ◯ ◯ capacity global X X X ◯ ◯ ◯ ◯ ◯ ◯ evaluation
[0582] [0582] TABLE 37 HF-type plain cable bundle × PVC-type adhesive tape (containing a copper damage inhibitor) type of wire harness Prior C. E. C. E. Art W3 W5 W6 E. W13 E. W14 E. W15 E. W16 E. W17 E. W18 HF-type plain cable bundle (30 electrical cables) type of Prior adhesive Art 3 C. E. 5 C. E. 6 E. 13 E. 14 E. 15 E. 16 E. 17 E. 18 tape experimental results 150° C., X ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ 96 hr, 10φ (cable) (cable) (cable) (cable) (cable) (cable) (cable) (cable) (cable) mandrel- winding wrapping ◯ X X ◯ ◯ ◯ ◯ ◯ ◯ operation appear- ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ ance gluing ◯ X X ◯ ◯ ◯ ◯ ◯ ◯ capacity global X X X ◯ ◯ ◯ ◯ ◯ ◯ evaluation
[0583] [0583] TABLE 38 HF-type plain cable bundle × HF-type adhesive tape (containing a copper damage inhibitor) type of wire harness Prior C. E. C. E. Art W4 W7 W8 E. W19 E. W20 E. W21 E. W22 E. W23 E. W24 HF-type plain cable bundle (30 electrical cables) type of Prior adhesive Art 4 C. E. 7 C. E. 8 E. 19 E. 20 E. 21 E. 22 E. 23 E. 24 tape experimental results 150° C., X ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ 96 hr, 10φ (cable) (cable) (cable) (cable) (cable) (cable) (cable) (cable) (cable) mandrel- X ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ winding (tape) (tape) (tape) (tape) (tape) (tape) (tape) (tape) (tape) wrapping ◯ X X ◯ ◯ ◯ ◯ ◯ ◯ operation appear- ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ ance gluing ◯ X X ◯ ◯ ◯ ◯ ◯ ◯ capacity global X X X ◯ ◯ ◯ ◯ ◯ ◯ evaluation
[0584] [0584] TABLE 39 HF-type plain cable bundle × PVC-type adhesive tape (containing an anti-oxidizing agent and a copper damage inhibitor) type of wire harness Prior C. E. C. E. Art W5 W9 W10 E. W25 E. W26 E. W27 E. W28 E. W29 E. W30 HF-type plain cable bundle (30 electrical cables) type of Prior adhesive Art 5 C. E. 9 C. E. 10 E. 25 E. 26 E. 27 E. 28 E. 29 E. 30 tape experimental results 150° C., X ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ 96 hr, 10φ (cable) (cable) (cable) (cable) (cable) (cable) (cable) (cable) (cable) mandrel- winding wrapping ◯ X X ◯ ◯ ◯ ◯ ◯ ◯ operation appeara- ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ nce gluing ◯ X X ◯ ◯ ◯ ◯ ◯ ◯ capacity global X X X ◯ ◯ ◯ ◯ ◯ ◯ evaluation
[0585] [0585] TABLE 40 HF-type plain cable bundle × HF-type adhesive tape (containing an anti-oxidizing agent and a copper damage inhibitor) type of wire harness Prior C. E. C. E. Art W6 W11 W12 E. W31 E. W32 E. W33 E. W34 E. W35 E. W36 HF-type plain cable bundle (30 electrical cables) type of Prior adhesive Art 6 C. E. 11 C. E. 11 E. 31 E. 32 E. 33 E. 34 E. 35 E. 36 tape experimental results 150° C., X ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ 96 hr, 10φ (cable) (cable) (cable) (cable) (cable) (cable) (cable) (cable) (cable) mandrel- X ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ winding (tape) (tape) (tape) (tape) (tape) (tape) (tape) (tape) (tape) wrapping ◯ X X ◯ ◯ ◯ ◯ ◯ ◯ operation appear- ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ ance gluing ◯ X X ◯ ◯ ◯ ◯ ◯ ◯ capacity global X X X ◯ ◯ ◯ ◯ ◯ ◯ evaluation
[0586] [0586] TABLE 41 (Mixed cable bundle of PVC-type electrical cables and HF-type electrical cables) × PVC-type adhesive tape (containing an anti-oxidizing agent) Prior Art W7 C. E. W13 C. E. W14 E. W37 E. W38 E. W39 E. W40 E. W41 E. W42 number ratio of PVC-type cables:HF-type cables 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1 10 29 1 10 29 1 10 29 1 10 29 1 10 29 1 10 29 1 10 29 1 10 1:29 29:1 20:10 1:29 type of adhesive tape Prior Art 1 C. E. 1 C. E. 2 E. 1 E. 2 E. 3 E. 4 E. 5 E. 6 150° C., X ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ 96 hr, (cable) (cable) (cable) (cable) (cable) (cable) (cable) (cable) (cable) 10φ mandrel- winding wrapping ◯ X X ◯ ◯ ◯ ◯ ◯ ◯ operation gluing ◯ X X ◯ ◯ ◯ ◯ ◯ ◯ capacity global X X X ◯ ◯ ◯ ◯ ◯ ◯ evaluation
[0587] [0587] TABLE 42 (Mixed cable bundle of PVC-type electrical cables and HF-type electrical cables) × HF-type adhesive tape (containing an anti-oxidizing agent) Prior Art W8 C. E. W15 C. E. W16 E. W43 E. W44 E. W45 E. W46 E. W47 E. W48 number ratio of PVC-type cables:HF-type cables 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1 10 29 1 10 29 1 10 29 1 10 29 1 10 29 1 10 29 1 10 29 1 10 1:29 29:1 20:10 1:29 type of adhesive tape Prior Art 2 C. E. 3 C. E. 4 E. 7 E. 8 E. 9 E. 10 E. 11 E. 12 150° C., X ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ 96 hr, 10φ (cable) (cable) (cable) (cable) (cable) (cable) (cable) (cable) (cable) mandrel- X ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ winding (tape) (tape) (tape) (tape) (tape) (tape) (tape) (tape) (tape) wrapping ◯ X X ◯ ◯ ◯ ◯ ◯ ◯ operation gluing ◯ X X ◯ ◯ ◯ ◯ ◯ ◯ capacity global X X X ◯ ◯ ◯ ◯ ◯ ◯ evaluation
[0588] [0588] TABLE 43 (Mixed cable bundle of PVC-type electrical cables and HF-type electrical cables) × PVC-type adhesive tape (containing a copper damage inhibitor) Prior Art W9 C. E. W17 C. E. W18 E. W49 E. W50 E. W51 E. W52 E. W53 E. W54 number ratio of PVC-type cables:HF-type cables 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1 10 29 1 10 29 1 10 29 1 10 29 1 10 29 1 10 29 1 10 29 1 10 1:29 29:1 20:10 1:29 type of adhesive tape Prior Art 3 C. E. 5 C. E. 6 E. 13 E. 14 E. 15 E. 16 E. 17 E. 18 150° C., X ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ 96 hr, 10φ (cable) (cable) (cable) (cable) (cable) (cable) (cable) (cable) (cable) mandrel- winding wrapping ◯ X X ◯ ◯ ◯ ◯ ◯ ◯ operation appear- ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ ance gluing ◯ X X ◯ ◯ ◯ ◯ ◯ ◯ capacity global X X X ◯ ◯ ◯ ◯ ◯ ◯ evaluation
[0589] [0589] TABLE 44 (Mixed cable bundle of PVC-type electrical cables and HF-type electrical cables) × HF-type adhesive tape (containing a copper damage inhibitor) Prior Art Art W10 C. E. W19 C. E. W20 E. W55 E. W56 E. W57 E. W58 E. W59 E. W60 number ratio of PVC-type cables:HF-type cables 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1 10 29 1 10 29 1 10 29 1 10 29 1 10 29 1 10 29 1 10 29 1 10 1:29 29:1 20:10 1:29 type of adhesive tape Prior Art 4 C. E. 7 C. E. 8 E. 19 E. 20 E. 21 E. 22 E. 23 E. 24 150° C., X ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ 96 hr, 10φ (cable) (cable) (cable) (cable) (cable) (cable) (cable) (cable) (cable) mandrel- X ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ winding (tape) (tape) (tape) (tape) (tape) (tape) (tape) (tape) (tape) wrapping ◯ X X ◯ ◯ ◯ ◯ ◯ ◯ operation appear- ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ ance gluing ◯ X X ◯ ◯ ◯ ◯ ◯ ◯ capacity global X X X ◯ ◯ ◯ ◯ ◯ ◯ evaluation
[0590] [0590] TABLE 45 (Mixed cable bundle of PVC-type electrical cables and HF-type electrical cables) × PVC-type adhesive tape (containing an anti-oxidizing agent and a copper damage inhibitor Prior Art Art W11 C. E. W21 C. E. W22 E. W61 E. W62 E. W63 E. W64 E. W65 E. W66 number ratio of PVC-type cables:HF-type cables 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1 10 29 1 10 29 1 10 29 1 10 29 1 10 29 1 10 29 1 10 29 1 10 1:29 29:1 20:10 1:29 type of adhesive tape Prior Art 5 C. E. 9 C. E. 10 E. 25 E. 26 E. 27 E. 28 E. 29 E. 30 150° C., X ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ 96 hr, 10φ (cable) (cable) (cable) (cable) (cable) (cable) (cable) (cable) (cable) mandrel- winding wrapping ◯ X X ◯ ◯ ◯ ◯ ◯ ◯ operation appear- ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ ance gluing ◯ X X ◯ ◯ ◯ ◯ ◯ ◯ capacity global X X X ◯ ◯ ◯ ◯ ◯ ◯ evaluation
[0591] [0591] TABLE 46 (Mixed cable bundle of PVC-type electrical cables and HF-type electrical cables) × HF-type adhesive tape (containing an anti-oxidizing agent and a copper damage inhibitor Prior Art Art W12 C. E. W23 C. E. W24 E. W67 E. W68 E. W69 E. W70 E. W71 E. W72 number ratio of PVC-type cables:HF-type cables 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1 10 29 1 10 29 1 10 29 1 10 29 1 10 29 1 10 29 1 10 29 1 10 1:29 29:1 20:10 1:29 type of adhesive tape Prior Art 6 C. E. 11 C. E. 12 E. 31 E. 32 E. 33 E. 34 E. 35 E. 36 150° C., X ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ 96 hr, 10φ (cable) (cable) (cable) (cable) (cable) (cable) (cable) (cable) (cable) mandrel- winding X ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ (tape) (tape) (tape) (tape) (tape) (tape) (tape) (tape) (tape) wrapping ◯ X X ◯ ◯ ◯ ◯ ◯ ◯ operation appear- ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ ance gluing ◯ X X ◯ ◯ ◯ ◯ ◯ ◯ capacity global X X X ◯ ◯ ◯ ◯ ◯ ◯ evaluation
[0592] [0592] TABLE 47 [Mixed cable bundle of PVC-type electrical cables (containing an anti-oxidizing agent) and HF-type electrical cables] × PVC- type adhesive tape (containing an anti-oxidizing agent) Prior Art Art W13 C. E. W25 C. E. W26 E. W73 E. W74 E. W75 E. W76 E. W77 E. W78 number ratio of PVC-type cables (containing an anti-oxidizing agent):HF-type cables 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1 10 29 1 10 29 1 10 29 1 10 29 1 10 29 1 10 29 1 10 29 1 10 1:29 29:1 20:10 1:29 type of adhesive tape Prior Art 1 C. E. 1 C. E. 2 E. 1 E. 2 E. 3 E. 4 E. 5 E. 6 150° C., X ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ 96 hr, 10φ (cable) (cable) (cable) (cable) (cable) (cable) (cable) (cable) (cable) mandrel- winding wrapping ◯ X X ◯ ◯ ◯ ◯ ◯ ◯ operation gluing ◯ X X ◯ ◯ ◯ ◯ ◯ ◯ capacity global X X X ◯ ◯ ◯ ◯ ◯ ◯ evaluation
[0593] [0593] TABLE 48 [Mixed cable bundle of PVC-type electrical cables (containing an anti-oxidizing agent) and HF-type electrical cables] × HF- type adhesive tape (containing an anti-oxidizing agent) Prior Art Art W14 C. E. W27 C. E. W28 E. W79 E. W80 E. W81 E. W82 E. W83 E. W84 number ratio of PVC-type cables (containing an anti-oxidizing agent):HF-type cables 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1 10 29 1 10 29 1 10 29 1 10 29 1 10 29 1 10 29 1 10 29 1 10 1:29 29:1 20:10 1:29 type of adhesive tape Prior Art 2 C. E. 3 C. E. 4 E. 7 E. 8 E. 9 E. 10 E. 11 E. 12 150° C., X ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ 96 hr, 10φ (cable) (cable) (cable) (cable) (cable) (cable) (cable) (cable) (cable) mandrel- winding X ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ (tape) (tape) (tape) (tape) (tape) (tape) (tape) (tape) (tape) wrapping ◯ X X ◯ ◯ ◯ ◯ ◯ ◯ operation gluing ◯ X X ◯ ◯ ◯ ◯ ◯ ◯ capacity global X X X ◯ ◯ ◯ ◯ ◯ ◯ evaluation
[0594] [0594] TABLE 47 [Mixed cable bundle of PVC-type electrical cables (containing an anti-oxidizing agent) and HF-type electrical cables] × PVC- type adhesive tape (containing a copper damage inhibitor) Prior Art Art W15 C. E. W29 C. E. W30 E. W85 E. W86 E. W87 E. W88 E. W89 E. W90 number ratio of PVC-type cables (containing an anti-oxidizing agent):HF-type cables 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1 10 29 1 10 29 1 10 29 1 10 29 1 10 29 1 10 29 1 10 29 1 10 1:29 29:1 20:10 1:29 type of adhesive tape Prior Art 3 C. E. 5 C. E. 6 E. 13 E. 14 E. 15 E. 16 E. 17 E. 18 150° C., X ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ 96 hr, 10φ (cable) (cable) (cable) (cable) (cable) (cable) (cable) (cable) (cable) mandrel- winding wrapping ◯ X X ◯ ◯ ◯ ◯ ◯ ◯ operation appear- ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ ance gluing ◯ X X ◯ ◯ ◯ ◯ ◯ ◯ capacity global X X X ◯ ◯ ◯ ◯ ◯ ◯ evaluation
[0595] [0595] TABLE 50 [Mixed cable bundle of PVC-type electrical cables (containing an anti-oxidizing agent) and HF-type electrical cables] × HF- type adhesive tape (containing a copper damage inhibitor) Prior Art Art W16 C. E. W31 C. E. W32 E. W91 E. W92 E. W93 E. W94 E. W95 E. W96 number ratio of PVC-type cables (containing an anti-oxidizing agent):HF-type cables 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1 10 29 1 10 29 1 10 29 1 10 29 1 10 29 1 10 29 1 10 29 1 10 1:29 29:1 20:10 1:29 type of adhesive tape Prior Art 4 C. E. 7 C. E. 8 E. 19 E. 20 E. 21 E. 22 E. 23 E. 24 150° C., X ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ 96 hr, 10φ (cable) (cable) (cable) (cable) (cable) (cable) (cable) (cable) (cable) mandrel- X ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ winding (tape) (tape) (tape) (tape) (tape) (tape) (tape) (tape) (tape) wrapping ◯ X X ◯ ◯ ◯ ◯ ◯ ◯ operation appear- ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ ance gluing ◯ X X ◯ ◯ ◯ ◯ ◯ ◯ capacity global X X X ◯ ◯ ◯ ◯ ◯ ◯ evaluation
[0596] [0596] TABLE 51 [Mixed cable bundle of PVC-type electrical cables (containing an anti-oxidizing agent) and HF-type electrical cables] × PVC- type adhesive tape (containing an anti-oxidizing agent and a copper damage inhibitor) Prior Art Art W17 C. E. W33 C. E. W34 E. W97 E. W98 E. W99 E. W100 E. W101 E. W102 number ratio of PVC-type cables (containing an anti-oxidizing agent):HF-type cables 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1 10 29 1 10 29 1 10 29 1 10 29 1 10 29 1 10 29 1 10 29 1 10 1:29 29:1 20:10 1:29 type of adhesive tape Prior Art 5 C. E. 9 C. E. 10 E. 25 E. 26 E. 27 E. 28 E. 29 E. 30 150° C., X ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ 96 hr, 10φ (cable) (cable) (cable) (cable) (cable) (cable) (cable) (cable) (cable) mandrel- winding wrapping ◯ X X ◯ ◯ ◯ ◯ ◯ ◯ operation appear- ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ ance gluing ◯ X X ◯ ◯ ◯ ◯ ◯ ◯ capacity global X X X ◯ ◯ ◯ ◯ ◯ ◯ evaluation
[0597] [0597] TABLE 52 [Mixed cable bundle of PVC-type electrical cables (containing an anit-oxidizing agent) and HF-type electrical cables] × HF- type adhesive tape (containing an anti-oxidizing agent and a copper damage inhibitor) Prior Art Art W18 C. E. W35 C. E. W36 E. W103 E. W104 E. W105 E. W106 E. W107 E. W108 number ratio of PVC-type cables (containing an anti-oxidizing agent):HF-type cables 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1: 29: 20: 1 10 29 1 10 29 1 10 29 1 10 29 1 10 29 1 10 29 1 10 29 1 10 1:29 29:1 20:10 1:29 type of adhesive tape Prior Art 6 C. E. 11 C. E. 12 E. 31 E. 32 E. 33 E. 34 E. 35 E. 36 150° C., X ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ 96 hr, 10φ (cable) (cable) (cable) (cable) (cable) (cable) (cable) (cable) (cable) mandrel- X ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ winding (tape) (tape) (tape) (tape) (tape) (tape) (tape) (tape) (tape) wrapping ◯ X X ◯ ◯ ◯ ◯ ◯ ◯ operation appear- ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ ance gluing ◯ X X ◯ ◯ ◯ ◯ ◯ ◯ capacity global X X X ◯ ◯ ◯ ◯ ◯ ◯ evaluation
[0598] [0598] TABLE 53 Experiment 1: PVC-type tapes (tape base: adsorbent + anti-oxidizing agent; adhesive: acrylic acid resin + adsorbent + anti-oxidizing agent) composition Prior (parts by weight) Art E. 1-1 E. 1-2 E. 1-3 E. 1-4 E. 1-5 E. 1-6 C. E. 1-1 C. E. 1-2 PVC tape base PVC(P: 1300) 100 100 100 100 100 100 100 100 100 DOP 60 60 60 60 60 60 60 60 60 calcium carbonate 20 20 20 20 20 20 20 20 20 stabilizer 5 5 5 5 5 5 5 5 5 anti-oxidizing agent — 5 5 5 5 5 5 5 5 carbon black — 1 10 150 — — — 160 — silica — — — — 1 10 150 — 160 total (parts by weight) 185 191 200 340 191 200 340 350 350 adhesive SBR 70 — — — — — — — — natural rubber 30 — — — — — — — — zinc white # 3 20 — — — — — — — — rosin-type resin 80 — — — — — — — — emulsion-type acrylic acid — 100 100 100 100 100 100 100 100 resin anti-oxidizing agent — 3 3 3 3 3 3 3 3 carbon black — 1 10 150 — — — 160 — silica — — — — 1 10 150 — 160 total (parts by weight) 200 104 113 253 104 113 253 263 263 experimental results 150° C., 96 hr, 10φ X ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ mandrel-winding (cable) (cable) (cable) (cable) (cable) (cable) (cable) (cable) (cable) wrapping operation ◯ ◯ ◯ ◯ ◯ ◯ ◯ X X global evaluation X ◯ ◯ ◯ ◯ ◯ ◯ X X
[0599] [0599] TABLE 54 Experiment 2: PVC-type tapes (tape base: adsorbent + copper damage inhibitor; adhesive: acrylic acid resin + adsorbent + copper damage inhibitor) composition Prior (parts by weight) Art E. 2-1 E. 2-2 E. 2-3 E. 2-4 E. 2-5 E. 2-6 C. E. 2-1 C. E. 2-2 PVC tape base PVC(P: 1300) 100 100 100 100 100 100 100 100 100 DOP 60 60 60 60 60 60 60 60 60 calcium carbonate 20 20 20 20 20 20 20 20 20 stabilizer 5 5 5 5 5 5 5 5 5 copper damage inhibitor — 1.6 1.6 1.6 1.6 1.6 1.6 1.6 1.6 carbon black — 1 10 150 — — — 160 — silica — — — — 1 10 150 — 160 total (parts by weight) 185 187.6 196.6 336.6 187.6 196.6 336.6 346.6 346.6 adhesive SBR 70 — — — — — — — — natural rubber 30 — — — — — — — — zinc white # 3 20 — — — — — — — — rosin-type resin 80 — — — — — — — — emulsion-type acrylic acid — 100 100 100 100 100 100 100 100 resin copper damage inhibitor — 1 1 1 1 1 1 1 1 carbon black — 1 10 150 — — — 160 — silica — — — — 1 10 150 — 160 total (parts by weight) 200 102 111 251 102 111 251 261 261 experimental results 150° C., 96 hr, 10φ X ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ mandrel-winding (cable) (cable) (cable) (cable) (cable) (cable) (cable) (cable) (cable) wrapping operation ◯ ◯ ◯ ◯ ◯ ◯ ◯ X X global evaluation X ◯ ◯ ◯ ◯ ◯ ◯ X X
[0600] [0600] TABLE 55 Experiment 3: PVC-type tapes (tape base: adsorbent + anti-oxidizing agent + copper damage inhibitor; adhesive: acrylic acid resin + adsorbent + anti- oxidizing agent + copper damage inhibitor) composition C. E. 3- C. E. (parts by weight) Prior Art E. 3-1 E. 3-2 E. 3-3 E. 3-5 E.3-6 1 3-2 PVC tape base PVC (P: 1300) 100 100 100 100 100 100 100 100 100 DOP 60 60 60 60 60 60 60 60 60 calcium carbonate 20 20 20 20 20 20 20 20 20 stabilizer 5 5 5 5 5 5 5 5 5 anti-oxidizing agent — 5 5 5 5 5 5 5 5 copper damage inhibitor — 1.6 1.6 1.6 1.6 1.6 1.6 1.6 1.6 carbon black — 1 10 150 — — — 160 — silica — — — — 1 10 150 — 160 total (parts by weight) 185 192.6 201.6 341.6 192.6 201.6 341.6 351.6 351.6 adhesive SBR 70 — — — — — — — — natural rubber 30 — — — — — — — — zinc white #3 20 — — — — — — — — rosin-type resin 80 — — — — — — — — emulsion-type acrylic acid — 100 100 100 100 100 100 100 100 resin anti-oxidizing agent — 3 3 3 3 3 3 3 3 copper damage inhibitor — 1 1 1 1 1 1 1 1 carbon black — 1 10 150 — — — 160 — silica — — — — 1 10 150 — 160 total (parts by weight) 200 105 114 254 105 114 254 264 264 experimental results 150° C., 96 hr, 10φ mandrel- X ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ winding (cable) (cable) (cable) (cable) (cable) (cable) (cable) (cable) (cable) wrapping operation ◯ ◯ ◯ ◯ ◯ ◯ ◯ X X global evaluation X ◯ ◯ ◯ ◯ ◯ ◯ X X
[0601] [0601] TABLE 56 Experiment 4: HF-type tapes (tape base: adsorbent + anti-oxidizing agent; adhesive: acrylic acid resin + adsorbent + anti-oxidizing agent) composition (parts by Prior E-4 C. E. C. E. weight) Art 1 E. 4-2 E. 4-3 E. 4-4 E. 4-5 E. 4-6 4-1 4-2 HF tape base polyolefin 100 100 100 100 100 100 100 100 100 bromine-type 3 3 3 3 3 3 3 3 3 flame retardant antimony 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 trioxide anti-oxidizing — 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 agent carbon black — 1 10 150 — — — 160 — silica — — — — 1 10 150 — 160 total (parts by 104.5 109 118 258 109 118 258 268 268 weight) adhesive SBR 70 — — — — — — — — natural rubber 30 — — — — — — — — zinc white#3 20 — — — — — — -—— rosin-type resin 80 — — — — — — — — emulsion-type — 100 100 100 100 100 100 100 100 acrylic acid resin anti-oxidizing —3 3 3 3 3 3 3 3 agent carbon black —1 10 150 — — — 160 — silica — — — — 1 10 150 — 160 total (parts by 200 104 113 253 104 113 253 263 263 weight) experimental results 150° C., 96 hr, X ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ 10φ mandrel- (cable) (cable) (cable) (cable) (cable) (cable) (cable) (cable) (cable) winding wrapping ◯ ◯ ◯ ◯ ◯ ◯ ◯ X X operation global X ◯ ◯ ◯ ◯ ◯ ◯ X X evaluation
[0602] [0602] TABLE 57 Experiment 5: HF-type tapes (tape base: adsorbent + copper damage inhibitor; adhesive: acrylic acid resin + adsorbent + copper damage inhibitor) composition (parts by Prior C. E. C. E. weight) Art E. 5-1 E. 5-2 E. 5-3 E. 5-4 E. 5-5 E. 5-6 5-1 5-2 HF tape base polyolefin 100 100 100 100 100 100 100 100 100 bromine-type 3 3 3 3 3 3 3 3 3 flame retardant antimony 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 trioxide copper damage — 1 1 1 1 1 1 1 1 inhibitor carbon black — 1 10 150 — — — 160 — silica — — — — 1 10 150 — 160 total (parts by 104.5 106.5 115.5 255.5 106.5 115.5 255.5 265.5 265.5 weight) adhesive SBR 70 — — — — — — — — natural rubber 30 — — — — — — — — zinc white# 3 20 — — — — — — — — rosin-type resin 80 — — — — — — — — emulsion-type — 100 100 100 100 100 100 100 100 acrylic acid resin copper damage — 1 1 1 1 1 1 1 inhibitor carbon black — 1 10 150 — — — 160 — silica — — — — 1 10 150 — 160 total (parts by 200 102 111 251 102 111 251 261 261 weight) experimental results 150° C., 96 hr, X ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ 10φ mandrel- (cable) (cable) (cable) (cable) (cable) (cable) (cable) (cable) (cable) winding wrapping ◯ ◯ ◯ ◯ ◯ ◯ X X operation global X ◯ ◯ ◯ ◯ ◯ ◯ X X evaluation
[0603] [0603] TABLE 58 Experiment 6: HF-type tapes (tape base: adsorbent + anti-oxidizing agent + copper damage inhibitor; adhesive: acrylic acid resin + adsorbent + anti- oxidizing agent + copper damage inhibitor) composition (parts by weight) Prior Art E. 6-1 E. 6-2 E. 6-3 E. 6-4 E. 6-5 E. 6-6 C. E. 6-1 C. E. 6-2 HF tape base polyfin 100 100 100 100 100 100 100 100 100 bromine-type 3 3 3 3 3 3 3 3 3 flame retardant antimony 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 trioxide anti-oxidizing — 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 agent copper — 1 1 1 1 1 1 1 1 damage inhibitor carbon black — 1 10 150 — — — 160 — silica — — — 1 10 150 — 160 total(parts by 104.5 110 119 259 110 119 259 269 269 weight) adhesive SBR 70 — — — — — — — — natural rubber 30 — — — — — — — — zinc white # 3 20 — — — — — — — — rosin-type 80 — — — — — — — — resin emulsion-type — 100 100 100 100 100 100 100 100 acrylic acid resin anti-oxidizing — 3 3 3 3 3 3 3 3 agent copper damage — 1 1 1 1 1 1 1 1 inhibitor carbon black — 1 10 150 — — — 160 — silica — — — — 1 10 150 — 160 total(parts by 200 105 114 254 105 114 254 264 264 weight) experimental results 150° C., 96 hr, X ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ 10φ mandrel- (cable) (cable) (cable) (cable) (cable) (cable) (cable) (cable) (cable) winding wrapping ◯ ◯ ◯ ◯ ◯ ◯ ◯ X X operation global X ◯ ◯ ◯ ◯ ◯ ◯ X X evaluation
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A harness-protecting material and wire harness comprises a base material which comprises two faces, at least one face of which is coated with an adhesive. The base material comprises a base organic material portion which includes a base polymer portion formed of a halogen-free resin or a substantially halogen-free resin. The adhesive comprises an adhesive adjuvant which contains at least one compound selected from the group consisting of a hydrogenated terpene-type resin, a hydrogenated aromatic resin, a hydrogenated aliplatic-type resin, a cumarone-indene type resin, a phenol-type resin and a styrene-type resin. The adhesive may contain acrylic acid-type resin as base polymer portion. The base material and/or adhesive may contain an anti-oxidizing agent, a copper damage inhibitor and/or an adsorbent. This abstract is neither intended to define the invention disclosed in this specification nor intended to limit the scope of the invention in any way.
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FIELD OF THE INVENTION
This invention relates to mooring lines. In particular, this invention relates to a retractable mooring line device for a boat or other watercraft.
BACKGROUND OF THE INVENTION
Mooring or docking a boat conventionally involves tying at least one mooring line between a cleat secured to the boat and a dock, pier, slip or other stationary mooring structure. This can be a difficult and trying task, particularly in rough water where the motion of the boat and slippery wet surfaces can render it difficult to properly secure the mooring line to the boat.
Moreover, the boat must be equipped with a mooring line of sufficient length to accommodate various mooring environments, although in many cases only a portion of the mooring line will be required to secure the boat. The excess mooring line can be difficult to stow neatly, and is thus subject to becoming knotted or tangled, or entangled with persons, cargo or equipment on the boat, which can pose both an inconvenience and a hazard.
Retractable mooring lines have been proposed, in which a line is wound about a payoff reel and dispensed as needed to moor the boat under the particular mooring conditions encountered at the time. An example of such a device is described and illustrated in U.S. Pat. No. 4,846,090 issued Jul. 11, 1989 to Palmquist, which is incorporated herein by reference, which teaches a spring-loaded reel biased in the take-up direction and provided with a ratchet-type lock that is selectively engaged to ratchet teeth provided along the edges of the reel guide walls, to prevent rotation in the payoff direction when the boat is moored.
However, the use of a ratchet-type lock with a spring-loaded payoff reel can cause problems due to the oscillating motion experienced by a moored boat in wavy conditions. Where the mooring structure is above the level of the securing point on the boat, as the boat is lifted upwardly by a wave the tension on the mooring line is temporarily released, which allows the reel to rotate in the take-up direction. As the crest of the wave passes, the boat begins to fall, but in the newly locked position of the reel the mooring line is too short to allow the boat to freely roll off of the wave, causing the boat to list away from the mooring structure. Similarly, where the mooring structure is below the level of the securing point on the boat, when the boat falls into a trough the tension on the mooring line is temporarily released, which allows the reel to turn in the take-up direction and locks the mooring line so that as the crest of the next wave arrives and lifts the boat the mooring line is too short to allow the boat to rise to the crest of the wave, causing the boat to list toward the mooring structure.
A retractable mooring line device which provides a positive lock against rotation of the payoff reel in both directions is described in U.S. Pat. No. 6,095,075 issued Aug. 1, 2000 to Gordon et al., which is incorporated herein by reference. This device is particularly suitable for light- and medium-duty applications. However, the latch engages only one wall of the payoff reel. A moored boat can be subjected to very high peak forces due to wave action and currents, and repetitive momentary tension on the mooring line is transferred to the payoff reel, which in turn subjects the locking mechanism to high momentary stresses. The payoff reel guide wall becomes subject to shearing or deformation and thus must be formed to a gauge sufficient to resist deformation under ordinary conditions.
It would accordingly be advantageous to provide a retractable mooring device with a payoff reel that can be locked in both the payoff and take-up directions and which provides a secure and stable lock simultaneously against both walls of the payoff reel, to effectively double the resistance to deformation of the reel under the stresses normally encountered by a mooring line, but in which the lock can be released with minimal effort.
SUMMARY OF THE INVENTION
The present invention overcomes the above disadvantages by providing a retractable mooring line device which locks the payoff reel against rotation in both the payoff and take-up directions. The locking mechanism in the device of the invention is sturdy and stable, yet easy to release.
The invention accomplishes this by providing a reel for storing and paying off the mooring line, having side walls each comprising a series of notches for receiving a releasable latch. The latch engages between notches at a substantially right angle, which provides a secure, positive locking engagement between the latch and the reel while permitting the latch to be released under the application of relatively little force.
In one preferred embodiment having a generally vertical orientation, and thus suitable for mounting internally within the gunnel or transom of a boat, the latch is actuated by a lever having a broad actuation plate which can be easily actuated by a user's hand or foot, and engages the reel radially. The latch is preferably biased to a locked position, i.e. with the latch engaging the reel, by a spring which bears against the gunnel plate, and thus the mechanism can be exposed for maintenance or repair simply by removal of the gunnel plate and the gunnel plate can then be reinstalled without requiring special loading or positioning of the latch spring.
In a further embodiment which is particularly suitable for mounting horizontally, for example within a pontoon of a pontoon or deck boat or the like, in which the latch is actuated by a button which can be actuated by a user's hand or foot. In this embodiment the latch moves axially relative to the reel and is provided with a pair of notches which align with the walls of the reel when the latch is in the release position. Preferably the latch is retained by the top plate and biased to the locked position by a spring which bears against the bottom of the housing, so in this embodiment after removing the housing the top plate can be removed and reinstalled without requiring special loading or positioning of the latch spring.
The present invention thus provides a retractable mooring line device, comprising a housing comprising side plates, a rotatable reel comprising sidewalls affixed in spaced relation to a hub, rotatably mounted to the side plates of the housing so that the reel is capable of rotating in two directions, the sidewalls each having a peripheral edge and a series of notches about each peripheral edge, and a locking mechanism comprising a latching member comprising a latch positioned and configured to move radially relative to the reel, between an unlocked position in which the latch disengages from the reel and a locked position in which the latch engages at least one of the series of notches about the peripheral edge of each of the side walls of the reel engaging both sidewalls to prevent rotation of the reel in both of the two directions, whereby when the latch is engaged to the notches of both sidewalls the reel is prevented from rotation in both of the two directions, and when the latch is disengaged from the notches of both sidewalls the reel is capable of rotation in two directions.
The present invention further provides a retractable mooring line device, comprising a housing comprising side plates and a gunnel plate affixed to a top edge of each side plate, a rotatable reel comprising sidewalls affixed in spaced relation to a hub, rotatably mounted to the side plates of the housing so that the reel is capable of rotating in two directions, the sidewalls each having a peripheral edge and a series of notches about each peripheral edge, and a locking mechanism comprising a latching member comprising an actuating plate exposed to an exterior of the housing and a latch disposed on opposed sides of the hub, the latch being positioned and configured to move radially relative to the reel, between an unlocked position in which the latch disengages from the reel and a locked position in which the latch engages at least one of the series of notches about the peripheral edge of each of the sidewalls of the reel engaging both sidewalls to prevent rotation of the reel in both of the two directions, the latching member comprising a spring bearing against the gunnel plate and urging the latch toward the locked position, whereby when the latch is engaged to the notches of both sidewalls the reel is prevented from rotation in both of the two directions, and when the latch is disengaged from the notches of both sidewalls the reel is capable of rotation in two directions.
The present invention further provides a retractable mooring line device, comprising a housing comprising side plates, a rotatable reel comprising sidewalls affixed in spaced relation to a hub, rotatably mounted to the side plates of the housing so that the reel is capable of rotating in two directions, the sidewalls each having a peripheral edge and a series of notches about each peripheral edge, and a locking mechanism comprising a latching member comprising a latch positioned and configured to move radially relative to the reel, between an unlocked position in which the latch disengages from the reel and a locked position in which the latch engages at least one of the series of notches about the peripheral edge of each of the sidewalls of the reel engaging both sidewalls to prevent rotation of the reel in both of the two directions, the latching member further comprising an actuating plate exposed to an exterior of the housing, the actuating plate and the latch being disposed on opposite sides of a hub, and the hub of the latching member is pivotally secured to the housing adjacent to the reel, whereby when the latch is engaged to the notches of both sidewalls the reel is prevented from rotation in both of the two directions, and when the latch is disengaged from the notches of both sidewalls the reel is capable of rotation in both of the two directions.
BRIEF DESCRIPTION OF THE DRAWING
In drawings which illustrate by way of example only preferred embodiments of the invention,
FIG. 1 is a perspective view of a first embodiment of the retractable mooring line device according to the invention, having a generally vertical orientation.
FIG. 2 is an end elevation of the device of FIG. 1 .
FIG. 3 is a partially exploded view of the device of FIG. 1 with one side plate removed to expose the moving parts of the device.
FIG. 4 is a partially exploded view of the reel and reel mounting mechanism.
FIG. 5 is an exploded view of a preferred embodiment of a spring for loading the reel.
FIG. 6 is an exploded perspective view of the spring and the reel.
FIG. 7 is a perspective view of the latching member.
FIG. 8 is a side elevation of the device of FIG. 1 with one side plate removed, showing the device in a fully unlocked position.
FIG. 9 is a side elevation of the device of FIG. 1 with one side plate removed, showing the device in a locked position; and
FIG. 10 is a side elevation of the device of FIG. 1 with one side plate removed, showing the device in a locked position with the safety latch engaged.
FIG. 11 is a perspective view of a further embodiment of the retractable mooring line device according to the invention, having a generally horizontal orientation.
FIG. 12 is a perspective view of the embodiment of FIG. 11 with the top plate removed.
FIG. 13 is a side elevation of the embodiment of FIG. 11 , showing the latch in the locked position.
FIG. 14 is a side elevation of the embodiment of FIG. 11 , showing the latch in the release position.
FIG. 15 is an end elevation of the embodiment of FIG. 11 .
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1 and 2 illustrate a first embodiment of the retractable mooring line device according to the invention. The device comprises a housing 10 comprising side plates 12 , 14 and a gunnel plate 16 . The side plates 12 , 14 are connected in spaced relation as by bolts 10 a extending through spacer sleeves 10 b , leaving sufficient clearance to allow free rotation of the reel 20 .
The gunnel plate 16 is preferably affixed to flanges 12 a , 14 a of the respective side plates 12 , 14 , as by bolts 16 a with countersunk heads exposed for removal in case the device requires maintenance or repair. An opening 16 c is provided in the gunnel plate 16 for the mooring line 2 , shown in phantom in FIG. 1 , to pass out of the housing 10 .
All components of the device are preferably composed of stainless steel, except as otherwise indicating in the following description. However, it will be appreciated that other materials may be suitable for any particular application, for example aluminium or plastic may be used for light duty applications, and the invention is not intended to be limited thereby.
The device may be housed in a plastic or fibreglass cup or casing 8 , as shown in FIG. 2 , which provides a drainage outlet 8 a to allow water to drain directly out of the hull of the watercraft, for example through a flexible hose 8 b.
The reel 20 , illustrated in FIG. 4 , comprises a pair of side walls 22 , 24 connected by (for example welded to) a hub 26 . The hub 26 fits snugly over a main bushing 28 , which is preferably composed of a self lubricating high density plastic, which in turn mounts over an axle or pin 30 rotationally fixed relative to the side plates 12 , 14 of the housing 10 . The hub 26 is rotationally locked to the main bushing 28 by one or more locking pins 26 a , and the bushing 28 remains free to rotate on pin 30 .
The reel is preferably spring loaded for automatic retraction when the locking mechanism (described below) is released. A spring 40 , illustrated in FIG. 5 , has a first anchoring end 40 a for engaging a slot 30 a or other engaging means at one end of the pin 30 , and a second anchoring end 40 b for engaging a slot 26 b or other engaging means in the hub 26 . Preferably the hub 26 is provided with a plurality of evenly spaced slots 26 b , so that the spring can be fixed to the hub 26 in one of a number of positions without requiring rotation of the reel 20 into a specific position. Also, preferably the spring 40 is contained within a casing 41 comprising a body 42 and a lid 44 , composed of the same self lubricating plastic as the bushing 28 . The casing 41 serves to both contain the spring against dislodgement when the reel 20 is removed from the housing 10 for servicing and to protect the spring 40 from salt water and the elements.
The encased spring 40 is thus inserted into the main hub 26 as shown in FIG. 6 . It will be appreciated that the main bushing 28 has an axial length less than that of the hub 26 , leaving sufficient space for the spring casing 41 to fit fully within the hub 26 .
In the preferred embodiment the pin 30 is rotationally fixed relative to the side plates 12 , 14 by a square end 30 b , best seen in FIG. 1 , which fits into a square opening in the side plate 12 and thus locks the pin 30 against rotation relative to the housing 10 . The reel 20 (and concurrently the main bushing 26 and spring casing 42 ) rotate around the pin 30 .
In the preferred embodiment the locking mechanism comprises a latching member 50 , illustrated in FIG. 7 , comprising an actuating plate 52 and a latch 54 disposed on opposite sides of a hub 56 . The latching member 50 is engaged to the side plates 12 , 14 as by pin 50 a , seen in FIG. 3 , so that as the actuating plate 52 is depressed into the housing 10 the latch 54 moves away from the side walls 22 , 24 to unlock the reel 20 .
An opening 16 b is provided in the gunnel plate 16 to expose the latching member 50 , preferably approximating the peripheral configuration of the actuating plate 52 for aesthetic reasons and to keep dirt out of the housing 10 .
A series of notches 60 is formed in the periphery of each of the side walls 22 , 24 of the reel 20 . Preferably the notches 60 are provided entirely around the periphery of each sidewall 22 , 24 , to maximize the number of positions in which the device can lock, separated by sufficient material to withstand the forces normally encountered by the watercraft when moored. The latch 54 is configured to simultaneously engage one of the notches 60 in each of the side walls 22 , 24 of the reel 20 . The latch 54 thus extends substantially across the entire interior of the housing 10 , which both ensures that the latch 54 engages both side walls 22 , 24 and allows some deflection of the latching member 50 without dislodging the latch 54 from the notches 60 .
The latching member 50 is accordingly mounted adjacent to the gunnel plate 16 , so as to pivot between the position in which the latch 54 is disengaged from the notches 60 as shown in FIG. 8 , which allows the reel 20 to rotate freely, and a position in which the latch 54 is engaged within a notch 60 in each side wall 22 , 24 , as shown in FIG. 9 , to lock the reel 20 against rotation in both directions. In the preferred embodiment the latching member 50 is mounted such that the actuating plate 52 is flush with the gunnel plate 16 when the device is in the locked position shown in FIG. 9 , and the latch 54 engages each notch 60 in a substantially perpendicular orientation.
Preferably the latching member 50 is spring biased to the locking position, so that the device locks automatically unless the actuating plate 54 is being depressed. In the preferred embodiment this is accomplished by affixing to the latching member 50 as by rivets or any other suitable means, a spring 70 , for example a leaf spring. Spring 70 is oriented such that the free end 72 of the spring 70 engages against the underside of the gunnel plate 16 . The pressure applied by the spring 70 can be optimized by separating the free end 72 of the spring 70 into a series of fingers 70 a , 70 b , 70 c , the width of each being selected so that the cumulative force supplied by the fingers 70 a , 70 b , 70 c provides the desired resistance to disengagement of the latching member 50 . This ensures that the latch 54 does not become dislodged from the notch 60 inadvertently, but at the same time minimizes the pressure required to release the latching member 50 .
In the preferred embodiment a maintenance lock 80 is also provided, rotatably mounted between the side plates 12 , 14 as by a pin 82 , in a position adjacent to the reel 20 . The maintenance lock 80 can thus be pivoted from the unlocked position, as shown in FIG. 9 , to a locked position shown in FIG. 10 in which the reel 20 is prevented from rotating regardless of the position of the latching member 50 . During normal operation of the device the maintenance lock 80 is retained in the unlocked position by a boss or stud 84 projecting from the side plate 12 and/or 14 into a hole 83 in the maintenance lock 80 . During maintenance or servicing the maintenance lock 80 can be rotated to the locked position and retained in the unlocked position by a boss or stud 85 projecting from the side plate 12 and/or 14 into the hole 83 in the maintenance lock 80 . The maintenance lock 80 is provided solely to prevent the reel 20 from uncoiling during servicing or repair activities, and is not used in normal operation.
In use, the gunnel plate 16 is attached to the side plate flanges 12 a , 14 a by bolts 16 a . The reel 20 is rotated a sufficient number of revolutions to retract the mooring line, 2 and the mooring line 2 is passed through the opening 16 and attached to the reel 20 . When the reel 20 is released the spring 40 rotates the reel in the take-up direction and the mooring line 2 is automatically loaded onto the hub 26 . The device is optionally placed in a water-catching container 8 and mounted into the gunnel 4 of a boat (shown in phantom in FIG. 2 ), preferably so that the upper surface of the gunnel plate 16 is flush with the gunnel 4 , and secured in place as by screws, rivets or other suitable fastening members (not shown) through holes 16 d.
When the watercraft is to be moored, the actuating plate 52 of the latching member 50 is depressed, which may be conveniently effected by the user's foot. The mooring line 2 is drawn out to the required length and affixed to a dock or other mooring structure (not shown). The spring 40 winds tighter as the mooring line 2 is drawn out, because the end 40 a engaging the pin 30 remains stationary while the end 40 b rotates with the hub 26 . The actuating plate 52 is released and the latch spring 70 urges the latch 54 into the next nearest notches 60 of the respective sidewalls 22 , 24 of the reel 20 , thus locking the reel 20 against rotation.
To retract the mooring line 2 , the actuating plate 54 is depressed to disengage the latch 54 from the notches 60 . The spring 40 rotates the reel 20 in the retracting direction to retract the mooring line 2 back onto the reel 20 for storage.
FIGS. 11 to 15 illustrate a further embodiment of the retractable mooring line device according to the invention. This embodiment has a generally horizontal orientation, which is particularly suitable for mounting on a watercraft via housing flange 10 a , for example onto the frame between pontoons of a pontoon boat or the like. In this embodiment a latch 90 comprises a latch plate 92 having notches 94 (best seen in FIG. 13 ) large enough to allow the sidewalls 22 , 24 of the reel 20 to pass freely through the notches 94 , and spaced apart a distance corresponding to the spacing between the sidewalls 22 , 24 . The latch 90 is slidably disposed through an opening (not shown) in the top plate 16 at any suitable position adjacent to the reel 20 , and movable between a locked position, shown in FIG. 13 , with the button 96 raised from the top plate 16 and the notches 94 out of alignment with the reel sidewalls 22 , 24 ; and a release position, shown in FIG. 14 , with the button 96 depressed and the notches 94 in alignment with the reel sidewalls 22 , 24 .
Preferably the latch 90 is biased to the locked position by one or more springs 98 (two springs 98 are shown in the embodiment illustrated, as best seen in FIG. 15 ), which bear against the bottom plate 18 of the housing 10 . Thus, in this embodiment also the top plate 16 can be removed and reinstalled (after demounting the housing from the frame of the boat) without requiring special loading or positioning of the latch spring 98 . As in the previously described embodiment, the button 96 can be actuated by a user's hand or foot. However, in the embodiment of FIGS. 11 to 15 the latch 90 moves axially relative to the reel 20 , releasing the reel 20 when the notches 94 are aligned with the reel sidewalls 22 , 24 , as shown in FIG. 14 .
In the operation of the embodiment of FIGS. 11 to 15 , the reel 20 is retained in the locked position by engagement of the latch plate 92 with one of the series of notches 60 disposed about the periphery of each sidewall 22 , 24 . When a user depresses the button 96 the latch plate 92 moves axially relative to the reel 20 until the notches 94 come into alignment with the sidewalls 22 , 24 , at which point the reel 20 is released and able to rotate in both directions.
In both of the described embodiments, servicing and maintenance of the device 10 is easily effected by removing bolts 16 a and removing the gunnel plate 16 , which exposes the entire interior of the housing 10 and all of the moving components of the device 10 .
Various embodiments of the present invention having been thus described in detail by way of example, it will be apparent to those skilled in the art that variations and modifications may be made without departing from the invention. The invention includes all such variations and modifications as fall within the scope of the appended claims.
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A retractable mooring line device comprising a reel for storing and paying off a mooring line, having side walls each comprising a series of notches for receiving a releasable latch. A latch simultaneously engages between notches in both side walls at a substantially right angle to provide a secure, positive locking engagement between the latch and the reel while permitting the latch to be released under the application of relatively little force. In the preferred embodiment the latch may be actuated by a user's hand or foot and is biased toward the reel by a spring which bears against the housing. The mechanism can be exposed for maintenance or repair simply by removal of the gunnel plate and reinstallation of the gunnel plate does not require special loading of the latch spring.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a stain-proofing agent (i.e. an agent which enables release of soils and stains by the action of water and the like) used for stain-proofing treatment of the surfaces, for example, of wood fiber cement boards, calcium silicate boards, cement (concrete) boards, metal plates or boards, or glass plates or boards, as well as to a building board treated with the stain-proofing agent.
2. Description of the Prior Art
Architectural substrate boards such as, for example, external wall materials such as siding boards are generally coated with a coating composition on their surfaces and are applied with a stain-proofing agent which forms a stain-proofing film having a self-cleaning function to remove stains adhered to the surfaces after attachment.
As this kind of stain-proofing agent has been used such an agent which forms a super hydrophilic stain-proofing film on the surface to be treated. Upon application of the stain-proofing agent onto the surface of a substrate, a super hydrophilic stain-proofing film is formed thereon. When stains are attached to the surface of the substrate, water applied to the surface is absorbed by the super hydrophilic stain-proofing film and, as a result, the stains float on the water and are washed away together with the water (i.e. self-cleaning effect).
In order to form a super hydrophilic stain-proofing film on the surface of a substrate, mainly an aqueous dispersion of silica fine particles (colloidal silica) has been hitherto used.
For example, Japanese Laid-open Patent Publication No. 6-71219 gazette (JP 6-71219 A) discloses a method for forming a stain-proofing film which comprises applying an aqueous dispersion of colloidal silica having an average particle diameter of not more than 100 nm to a coat of an aqueous emulsion of a synthetic resin to form a film of colloidal silica on the surface of the coat.
Japanese Laid-open Patent Publication No. 2002-338943 gazette (JP 2002-338943 A) discloses a method for forming a stain-proofing layer which comprises applying a liquid containing colloidal silica and an alumina/aluminum-magnesium composite oxide for providing water-proof and alkali-proof properties to the coated surface.
The above-described silica fine particles give super hydrophilicity to the treated surface of the substrate owing to the presence of silanol group on the surface of the particles.
SUMMARY OF THE INVENTION
The above-described silica fine particles contain a number of vicinal silanol groups in which silanol groups present on the surface of the particles are adjacent closely to one another and the vicinal silanol groups are mutually hydrogen-bonded. Since the vicinal silanol groups are decreased in free silanol group (i.e. single silanol group) which participates in hydrophilicity and have low surface activity, the fixing property of the silica fine particles to the surface of a substrate is insufficient. Thus the silica fine particles are liable to flow out upon exposure to rain water, and thus long-term stain-proofing effect is not expectable. In order to obtain a stain-proofing film having high hydrophilicity, it is necessary to increase the concentration of silica fine particles in the aqueous dispersion since the concentration of single silanol group contained in the silica fine particles is not so high. However, if the concentration of silica particles is increased, the resulting aqueous dispersion becomes expensive.
In addition, silica fine particles have a particle diameter on the order of nanometer (not more than 100 nm). Therefore, when a coating composition is applied to the surface of a substrate and then stain-proofing treatment is effected thereon, silica particles may be involved in expansion and contraction of the coat caused by absorption and desorption of moisture and a change in environmental temperature and thus may be embedded in the coat to decrease their stain-proofing effect.
As a means to solve the above-described conventional problems, the present invention provides a stain-proofing agent which forms a super hydrophilic stain-proofing film upon application to a surface of a substrate, which comprises using fumed silica dispersed in an aqueous solvent. The aqueous solvent is preferably a mixed solvent of water and an alcohol, and is more preferably incorporated with a surfactant additionally.
According to the present invention, there is also provided a building board having a super hydrophilic stain-proofing film formed by applying the above-described stain-proofing agent on a surface of a substrate followed by drying. Preferably, a coating composition is applied onto the surface of the substrate and the stain-proofing agent is applied onto the resulting coat while it is in semi-drying state followed by heating and drying. A wood fiber cement board suitable for external wall members or the like is suitable as the substrate of the building board.
Mode of Action
Fumed silica is prepared by, for example, hydrolyzing silicon tetrachloride in oxygen-hydrogen flame. The particle diameter of the primary particle thereof is in a range of from about 7 to 40 nm. When it is dispersed in an aqueous solvent, particles associate to form a network structure and give secondary particles having a particle diameter of several hundreds nanometers (about 500 nm).
Even in such association state of the particles, fumed silica contains free silanol groups (single silanol groups) on the surface thereof in a high concentration, has a high activity and gives a high super hydrophilicity to the surface of the substrate. In addition, owing to a high surface activity and formation of a network structure upon association, the apparent molecular weight increases. Owing to the high surface activity and increased apparent Van der Waals force, fixing property of fumed silica to the substrate surface is increased, and the substrate surface can retain good super hydrophilicity, i.e. stain-proofing property, for a long period of time.
When a building board is used as a substrate and a coating composition is applied to the surface of the building board and then the stain-proofing agent is applied while the resulting coat is in semi-dried state, namely, the stain-proofing agent is applied while the coat on the surface of the substrate is in a semi-hardened state and is adhesive, the fumed silica is slightly embedded in the coat, whereby the adhesion of the resulting stain-proofing layer to the coat is enhanced. Since the fumed silica has become bulky upon association of the particles as described above, it is not totally embedded in the coat although it may somewhat get thereinto. Even if the coat expands or contracts due to absorption or desorption of moisture or change in environmental temperature, the fumed silica is not involved in the coat and not totally embedded therein, whereby stain-proofing property is not lowered.
When the stain proofing agent is a dispersion of fumed silica in a solvent containing an alcohol, water and preferably a surfactant, wettability of the agent with the coat is enhanced owing to the surface tension-lowering action of the alcohol and the surfactant and the affinity to the coat is increased, thereby increasing the adhering force of the formed stain-proofing layer to the coat. Moreover, the fumed silica is uniformly dispersed without settling down by the presence of the surfactant.
Effect
Since fumed silica containing a number of single silanol groups present on the surface is used in the stain-proofing agent of the present invention, the stain-proofing agent has a high fixing property to a substrate and exhibits significant lasting stain-proofing effect.
DETAILED DESCRIPTION OF THE INVENTION
The invention will be explained below in detail.
[Fumed Silica]
The fumed silica used in the present invention can be prepared by burning and hydrolyzing a volatile silicon compound such as silicon tetrachloride in a gas phase in, for example, oxygen-hydrogen flame as described above.
Primary particle diameter of the fumed silica is in a range of from about 7 to 40 nm. However, when it is dispersed in an aqueous solvent, the particles associate to form network structures and provide secondary particles of several hundreds nanometers (about 500 nm) in diameter.
The fumed silica has a specific surface area in a range of from about 500,000 to 2,000,000 cm 2 /g and contains 2 to 3, or more, as necessary, single silanol groups per nm 2 . Thus, the fumed silica has a high surface activity and imparts high super hydrophilicity to the surface of a substrate.
[Alcohol]
In the present invention, it is desirable to add an alcohol to water as a solvent for dispersing the fumed silica. The alcohol used in the present invention is desirably a water-soluble alcohol such as methanol, ethanol or isopropanol. The alcohol lowers the surface tension of the stain-proofing agent of the present invention and increases affinity of the agent to an underlaying substrate or a coat formed on the substrate, thereby enhancing wettability of the agent.
[Surfactant]
The stain-proofing agent of the present invention is desirably incorporated with a surfactant. As the surfactant may be used any of usual anionic, nonionic and cationic surfactants. Examples of the anionic surfactant include higher alcohol sulfates (Na salts or amine salts), alkylally sulfonates (Na salts or amine salts), alkylnaphthalene sulfonates (Na salts or amine salts), alkylnaphthalene sulfonate condensates, alkyl phosphates, dialkyl sulphosuccinates, rosin soaps, and fatty acid salts (Na salts or amine salts). Examples of the nonionic surfactant include polyoxyethylene alkyl ethers, polyoxyethylene alkyl phenol ethers, polyoxyethylene alkyl esters, polyoxyethylene alkyl amines, polyoxyethylene alkylol amines, polyoxyethylene alkyl amides, sorbitan alkyl esters, and polyoxyethylene sorbitan alkyl esters. Examples of the cationic surfactant include octadecyl amine acetates, acetates of imidazoline derivatives, polyalkylene polyamine derivatives and their salts, octadecyltrimethyl ammonium chloride, trimethylaminoethylalkyl amide halogenides, alkyl pyridium sulfates, and alkyltrimethyl ammonium halogenides. A mixture of two or more of the surfactants may be used. These examples do not restrict the invention.
Both the surfactant and the alcohol lower surface tension of the stain-proofing agent of the present invention, favorably disperse the fumed silica in the agent, and increase affinity to the underlying coat.
The stain-proofing agent of the present invention usually contains 0.1 to 10% by mass, preferably 0.5 to 6% by mass of the fumed silica, 2 to 10% by mass of the alcohol, and 0.01 to 0.25% by mass of the surfactant, the remainder being water.
If the alcohol is contained in an amount of less than 2% by mass, wettability of the stain-proofing agent deteriorates, whereas if it is contained in an amount of more than 10% by mass, volatility of the resulting solvent becomes so high as to adversely affect coating operation. If the surfactant is contained in an amount of less than 0.01% by mass, surface tension-lowering effect and fumed silica-dispersing effect brought about by the surfactant are not remarkable whereas if it is contained in an amount of more than 0.25% by weight, the resulting stain-proofing layer is adversely affected in terms of strength, water resistance, durability and the like. Thus, it is desirable that the agent has a surface tension not more than 20 dyne/cm at 25° C.
The substrate to be applied with the stain-proofing agent of the invention is principally a building board such as an external wall material. As the building board may be used a wood fiber cement board prepared by molding and hardening a mixture mainly consisting of a wood reinforcing material such as wood chip, wood fiber bundle, wood pulp, wood-wool, or wood flour and a hydraulic cement material, and the surface of the wood fiber cement board may have a concavo-convex pattern formed by embossing or the like. Coating is applied onto the surface of the board. Coating is effected by using an organic coating composition such as an acrylic resin coating composition, an acryl-silicone resin coating composition, or an acryl-urethane resin coating composition, or an inorganic coating composition such as a phosphate-based coating composition, or a metal oxide-based coating composition. Usually, three-ply coating consisting of under coating, intermediate coating and top coating, or two-ply coating consisting of under coating and top coating is applied.
As the coating composition used for the coating, it is desirable to use an aqueous emulsion coating composition such as a coating composition of an aqueous emulsion of acrylic resin. This is because a coat formed by the aqueous emulsion coating composition contains a hydrophilic component such as a surfactant and thus has a high affinity to the aqueous stain-proofing agent.
In the present invention, the stain-proofing agent is applied to a coat formed by applying a coating composition to the surface of the substrate while the coat is in semi-dried state, namely, semi-hardened state. In the case of two-ply or three-ply coating, the stain-proofing agent is applied while the coat formed by top coating is in semi-dried state.
The “coat in semi-dried state” means a state in which a solvent or water is not completely evaporated in the case where a solvent type coating composition or an aqueous emulsion coating composition is used, or a state in which a resin vehicle or an inorganic vehicle in a coating composition is not completely hardened, i.e. in semi-hardened state, in the case where a solvent-free type coating composition is used.
The semi-dried state of a coat is usually realized in 10 to 60 seconds after formation of the coat by coating. When a solvent type coating composition or an aqueous emulsion coating composition is used, the solid content increases from 30-50% by mass to 60-80% by mass during this period.
In the semi-dried state of the coat, fumed silica in the stain-proofing agent slightly gets into the coat, and thus the adhesive force of the stain-proofing layer to the coat is enhanced without causing mixing of the stain-proofing layer and the coat.
The substrate to be used in the invention other than the above-mentioned building boards includes, for example, calcium silicate boards, cement (concrete) boards, metal boards or plates and glass boards or plates.
A method desirable for applying the stain-proofing agent to the surface of the substrate includes spray coating. The spray coating includes, for example, low pressure airless spray coating, coating by means of a Bell type coating machine and electrostatic coating. The other coating methods may include brushing, roll coater coating, and knife coater coating.
In the spray coating, the stain-proofing agent is atomized to mist and the mist adheres to the surface of the substrate with a concavo-convex patter, whereby the agent is readily fixed to the surface.
EXAMPLES 1-11, COMPARATIVE EXAMPLES 1-3
Stain-proofing agents were prepared by adding the components shown in Table 1 to water and mixing them.
For dispersion of fumed silica, a bead mill was used and then dispersion by means of ultrasonic wave was effected for 40 minutes. Onto the surface of a wood fiber-containing calcium silicate board was applied an aqueous styrene-acrylic coating composition to give a substrate to be used for confirming stain-proofing effect of the present invention.
Each of the stain-proofing agents having a composition shown in Table 1 was applied to the surface of the substrate prepared as described above in an amount of 5 g of the stain-proofing agent per sq.ft, and the coated substrate was dried at normal temperature for use in a test.
TABLE 1 Comparative Component Example Example (% by mass) 1 2 3 4 5 6 7 8 9 10 11 1 2 3 Fumed 0.5 1.5 2 4 6 0.5 1.5 2 0.5 1.5 2 0 silica Colloidal 2 6 silica Surfactant* 0.2 0.2 0.2 Isopropyl 5 5 5 5 5 alcohol *sodium lauryl sulfonate
Test 1
Each of the test samples of Examples 1-11 and Comparative Examples 1-3 thus prepared was fixed to a stand to face toward the south and have a tilt angle of 30°, and exposed to the outside air for two months to confirm the stain-proofing effect thereof. For evaluation of the degree of stain, a difference (ΔL) in lightness (L value) measured by Minoruta color difference meter CR 300 was used. The results are shown in Table 2.
Test 2
Each of the test samples of Examples 1-11 and Comparative Examples 1-3 prepared under similar conditions was washed with water under high pressure for 1 minute, and change in the contact angle between water and the test sample before and after washing was measured to confirm hydrophilization effect. The results are shown in Table 2.
Test 3
Each of the test samples of Examples 1-11 and Comparative Examples 1-3 prepared under similar conditions was immersed in water kept at 25° C. for three days, and change in the contact angle between water and the test sample before and after immersion was measured to confirm hydrophilization effect. The results are shown in Table 2.
TABLE 2 Comparative Example Example 1 2 3 4 5 6 7 8 9 10 11 1 2 3 Test 1 Δ L 4.8 3.2 1.6 1.5 1.3 4.5 3.3 1.8 4.4 3.6 2.0 6.5 4.1 1.8 Test 2 Contact Before 0 0 0 0 0 0 0 0 0 0 0 81 0 0 angle θ washing (°) After 58 25 0 0 0 36 20 0 55 31 0 72 45 20 washing Test 3 Contact Before 0 0 0 0 0 0 0 0 0 0 0 88 0 0 angle θ immersion (°) After 62 32 0 0 0 49 26 0 58 30 0 70 42 22 immersion
Results of Test 1
Referring to Table 2, the ΔL Of the test sample of Comparative Example 1 which has not been treated is as high as 6.5; the ΔL (4.1) of the test sample of Comparative Example 2 which has been treated with the stain-proofing agent containing 2% by mass of colloidal silica is approximately the same as the ΔL (4.4) of the test sample of Example 9 which has been treated with the stain-proofing agent containing 0.5% by mass of fumed silica; the ΔL (1.8) of the test sample of Comparative Example 3 which has been treated with the stain-proofing agent containing 6% by mass of colloidal silica is the same as the ΔL (1.8) of the test sample of Example 8 which has been treated with the stain-proofing agent containing 2% by mass of fumed silica; the ΔL (1.6) of the test sample of Example 3 which has been treated with the stain-proofing agent containing 2% by mass of fumed silica is far less than the ΔL (4.1) of the test sample of Comparative Example 2; and the ΔL (1.3) of the test sample of Example 5 which has been treated with the stain-proofing agent containing 6% by mass of fumed silica is less than the ΔL (1.8) of the test sample of Comparative Example 3. Thus, it is confirmed that a stain-proofing agent containing fumed silica exhibits more durable stain-proofing effect than that containing colloidal silica.
Results of Tests 2 and 3
With regard to Test 2, the contact angle θ of the test sample of Comparative Example 1 which has not been treated is as high as 81° before washing and is slightly lowered to 72° after washing. All of the test samples of Comparative Example 2 and 3 in which colloidal silica is used and those of Examples 1-11 in which fumed silica is used have a contact angle θ of 0° (θ=0°) before washing, and exhibit good hydrophilicity. After washing, however, θ=45° in Comparative Example 2 as compared to θ=0° in Example 3, showing that the surface treated with a stain-proofing agent containing fumed silica has a larger hydrophilicity than the surface treated with a stain-proofing agent containing colloidal silica after washing. In Test 3, the test sample of Comparative Example 1 which has not been treated exhibits a contact angle value as large as 88° (θ=88°) before immersion and 70° (θ=70°) after immersion; all the test samples of Comparative Examples 2 and 3 as well as Examples 1-11 have a contact angle value of 0° (θ=0°) before immersion, showing good hydrophilicity, whereas, after immersion, θ=42° in Comparative Example 2, θ=0° in Example 3, θ=22° in Comparative Example 3 and θ=0° in Example 5, which shows that the surface treated with a stain-proofing agent using colloidal silica is largely decreased in hydrophilicity by immersion in water.
INDUSTRIAL APPLICABILITY
The surface of a substrate treated with the stain-proofing agent of the present invention exhibits durable stain-proofing property and the stain-proofing agent is useful for building materials such as external wall materials which are exposed to the outside air.
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Provided is a stain-proofing agent which forms a super hydrophilic stain-proofing film upon application to a surface of a substrate, which comprises using fumed silica dispersed in an aqueous solvent.
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BACKGROUND OF THE INVENTION
This invention relates to an engine throttle actuator control system as part of a vehicle traction control system, and more specifically, to an engine throttle actuator where the position of the engine throttle is controlled primarily by an input from the vehicle driver which is then reduced by intervention of an engine throttle actuator whose operation is controlled by the vehicle traction control system and the feedback control system of the present invention.
DESCRIPTION OF THE PRIOR ART
There presently exists both open and closed loop controlled throttle electromechanical actuator devices for intervening in the mechanical actuation of a vehicle throttle normally directly controlled by driver input from an accelerator pedal typically connected to the throttle by a tension cable. Recent traction control systems have included electronically controlled actuator mechanisms that serve to reduce the opening of the engine throttle independent of the driver's input in response to a position signal generated by an electronic control unit to effectuate a reduction in engine power upon loss of vehicle traction. Under certain operating conditions, one aspect of a vehicle traction control system is to provide an automatic reduction of the opening of the engine throttle so as to reduce engine power to assist in maintaining vehicle control.
One method of accomplishing this result is to provide a pivoted bellcrank or lever that can be transversely moved relative to the accelerator pedal so as to reduce the engine throttle position upon activation of the device upon command from an electronic control unit. These actuators have operated in an open loop manner where the position of the actuator depends on the force applied to a motor and the input electrical power. In some other advanced systems, the electronic control unit operates to position the actuator in a continuous mode by monitoring the output of wheel speed sensors and making real time adjustments in the electrical power to the actuator in an appropriate manner to reduce or limit engine power by closing the throttle without regard to the position of the throttle actuator device.
Such existing single traction control loop control approaches do not allow the relationship between driver's accelerator pedal and the intervention input to be tailored to provide the desired characteristics and "feel" for the driver. Also, the single traction control loop, replete with many time lags and resiliences including induction, combustion, inertia and driveline wrap-up, is required to perform all the requirements of the system in a single algorithm.
In order to provide traction control, which ideally requires the almost instantaneous reduction of engine power through closure of the throttle valve, it is necessary to incorporate an actuator type device that has a very quick response. U.S. Pat. No. 4,950,965, the disclosure of which is expressly incorporated herein by reference, discloses such a throttle control actuator of the type that uses a pivoted lever riding on a lead screw which is rotated by the action of a high speed DC motor. This type of mechanism has a particularly fast response time where the pivoted lever can be moved from one extreme of the lead screw to the other extreme in approximately 150 milliseconds. To maintain a quick response time, it is necessary to run the motor at a high rate of speed continuously until the desired position of the mechanism is obtained. This requires a sophisticated position feedback control system with the proper compensation for stability.
Control systems to date have been inadequate to provide quick response with accurate position and stability when a high speed DC motor driven cable intervention device is used to reduce the engine throttle position for use with a traction control system on a vehicle. Due to the high speed nature of the motor, the momentum of the motor and mechanism causes control problems. Simple reduction or elimination of the DC electrical current to the motor is an inadequate method of control when fast response times are desired, since when the current to the motor is simply reduced or eliminated, the momentum of the motor and mechanism causes the pivoted lever to travel past the requested position. One solution to this problem is to simply reduce or eliminate electrical power to the motor much earlier than the requested position allowing the lever to coast and hopefully stop at the proper position on the lead screw. The problem with this is that, depending on the positional history of the mechanism, the speed and momentum of the motor mechanism will change just prior to the point of desired position and an accurate time for power reduction and elimination is difficult to calculate. Another problem with this approach is that the response time of the mechanism is increased due to the early reduction or elimination of motor power thereby compromising the effectiveness of the traction control system.
Another type of mechanical mechanism to axially position a lever fulcrum is disclosed in application U.S. Ser. No. 07/736,659 filed Jul. 26, 1991, now U.S. Pat. No. 5,161,504, entitled "Dual Mode Electrical Servoactuator" by which would also show a performance gain if an advanced control system could be applied.
Another type of mechanical mechanism is disclosed in U.S. Pat. No. 4,940,109, the disclosure of which is hereby expressly incorporated by reference, which cooperates with the present invention to control the force experienced by the driver at the accelerator pedal.
SUMMARY OF THE INVENTION
The present invention is an electronic means of providing controlled electrical power to an electric motor driven engine throttle position control mechanism to allow high speed response with accurate positioning. Position feedback control loops inside the outer traction control loop, are used with feedback compensation and/or a limiting value to modify the input command signal from a vehicle electronic control unit which can be either an intervention actuator position command or a throttle limit position command so that the engine throttle responds in a fashion to reduce the vehicle engine power according to a traction control algorithm.
By using the present invention, relationships between accelerator input combined with traction loop input to throttle position output can be exactly and rapidly tailored to provide the characteristics and driver feel desired which may vary with type of vehicle. What is desired for a sedan may not be the same as that for a high performance car. The slower main traction loop is left free to process the wheel speed signals and to take traction control action without having to remain excessively busy at the actuator control level.
Due to the high speed nature of the mechanism, it is necessary to provide a special control feedback feature that brakes the DC motor by reversing the motor applied voltage to provide accurate positioning with quick response. This technique minimizes the response time of the actuator so that the engine throttle position is controlled as fast as possible thereby enhancing the effectiveness of the traction control algorithm. By using the control techniques of the present invention, it is possible to minimize the response time while retaining accurate position and control accuracy required with such systems.
Due to the mechanical nature of the actuators described in U.S. Pat. No. 4,950,965 and pending application U.S. Ser. No. 07/736,659 filed Jul. 26, 1991, now U.S. Pat. No. 5,161,504, when excessive intervention is attempted, the cable running from the accelerator pedal to the actuator and/or the cable running from the actuator to the throttle can go slack and the force at the accelerator pedal changes dramatically which are both undesirable from an operational viewpoint. By using the control techniques of the present invention, the position of the actuator can be controlled to eliminate this slack cable and/or accelerator pedal force problem.
Some traction control algorithms output a control signal that sets the desired position of the throttle control actuator whereas in other traction control strategies, the output is in the nature of the desired engine throttle position limit. One embodiment of the present invention accepts an actuator position control signal from the traction electronic control unit and, using the feedback control loop, positions the actuator in accordance with that command. In the second embodiment, the actuator responds to a throttle position command signal from the traction electronic control unit and positions the actuator so as to limit throttle opening to the position command signal.
One provision of the present invention is to provide a closed loop position control system for an engine throttle actuator where the speed of response is maximized by using reverse voltage braking of a DC motor.
Another provision of the present invention is to provide a position feedback control system to an engine throttle actuator where the actuator movement is limited so as to eliminate excessive intervention travel into an undesirable region.
Still another provision of the present invention is to provide a closed loop feedback control for an engine throttle actuator where the position command of the engine throttle valve is used to determine the position of the actuator.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic view of an embodiment of the present invention utilizing a single position feedback control loop from the DC motor powered actuator;
FIG. 2 is a graph showing the DC Motor Current and the Servoactuator Position versus Time of the present invention;
FIG. 3 is a schematic view of an embodiment of the present invention utilizing a second feedback control loop based on the position of the throttle plate and serving as a travel limit to the actuator and the feedback control loop shown in FIG. 1;
FIG. 4 is a graph showing the Throttle Position versus Accelerator Position for various Servoactuator Positions of the present invention;
FIG. 5 is a schematic view of an embodiment of the present invention having a single feedback control loop based on the position of the engine throttle plate;
FIG. 6 is a schematic view of an embodiment of the present invention utilizing a second feedback control loop based on the position of the DC motor powered actuator and the feedback control loop shown in FIG. 5.
FIG. 7 is a schematic view of an embodiment of the present invention utilizing a position control system based on the feedback signal from the throttle actuator and the engine throttle similar to that shown in FIG. 4 applied to a throttle actuator of the type employing a movable fulcrum member having a lever arm pivoted thereon.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a schematic view of the present invention where a DC motor powered actuator (2) is connected both to an accelerator pedal (16) by way of an accelerator throttle cable (18) and then to an intervention output cable (30) which is connected to and which controls the engine throttle plate (33). Under normal operation, the engine throttle plate (33) moves in proportion to the position of the driver's foot on accelerator pedal (16) through action of accelerator throttle cable (18) and intervention output cable (30). Upon the happening of a particular event, such as the excess spinning of the drive wheels of the vehicle, an electronic traction control unit issues an actuator position command signal (4) that is fed to an input summing junction (6) which generates a summing junction output (8) which is fed to a signal power amplifier (10) where the amplifier output (12) powers a DC motor (14) which drives the actuator mechanism (20). Without further control, such as the control system of the present invention, the servoactuator mechanism would travel to and hold at an unspecified position upon termination of the actuator position command signal (4).
The actuator output cable (30) is attached at one end to the actuator mechanism (20) and at a second end to the throttle valve (33) which resides in the throttle housing (32) which controls the airflow into an engine. The position of the actuator mechanism (20) is measured by an actuator position sensor (21) whose position sensor output (22) is fed to a mathematical function known as the actuator position feedback dynamic compensator (24) where it is mathematically manipulated and in turn, generates an actuator position feedback signal (26) which is then fed back to the input summing junction (6) where it is subtracted from the actuator position command signal (4). A different dynamic compensation equation is used depending on the direction of the actuator mechanism (20) travel.
The effect is that by utilizing the feedback control system of the present invention, the position of the actuator mechanism (20) is accurately positionally controlled according to the actuator position command signal (4) by the feedback loop based on the actuator position sensor (21) so that the DC motor (14) is powered until the desired position is reached and then the input power is removed until a new command signal is generated. The DC motor (14) is powered at a high level by the signal power amplifier (10) until nearly reaching the desired position as set by the actuator position command signal (4) and then the current is rapidly decreased and can reverse to provide a braking effect to further slow the speed of the actuator mechanism (20) as it nears the desired position. In this manner, the speed of response of the throttle actuator to a command signal (4) is maximized while providing for very accurate positioning.
FIG. 2 shows a graph of the actuator DC motor current (56) and actuator position (58) versus time. The DC motor current (56) is plotted on the ordinate (52) while time is on the abscissa (54). The DC motor current (52) range spans both negative and positive values as illustrated by the current time history as shown by the DC motor current (56) which starts out near zero level. The actuator position is shown on the same graph as dashed line (58) where the actuator starts at a position and then with time gradually moves to a second position and stabilizes out at that second position.
Upon signal from the electronic control unit, an actuator position command signal (4) is inputted into the throttle actuator control system (2). At that point DC motor current (56) increases in value from zero in a positive direction and the actuator position changes as illustrated by the break in the dashed line actuator position (58). As motor speed increases, the DC motor current falls to a nominal positive level where it continues for some period of time until the actuator position nears the final stabilized desired value as determined by the actuator position command signal (4) whose amplitude is decreasing due to the actuator position feedback signal (26). At this point, negative voltage is inputted into the DC motor (14) and the DC motor current reverses direction. Thus, the motor wants to reverse direction of rotation so as to dramatically oppose the motion of the actuator mechanism (20) which is being affected by the momentum of both the DC motor (14) and the actuator mechanism (20). To account for the momentum effect of the DC motor (14) and the actuator mechanism (20), the actuator position feedback compensator (24) calculates a momentum term based on the time derivative of position and applies that as a part of the compensator which mathematically manipulates the actuator position feedback signal so that the actuator mechanism (20) is rapidly braked as it approaches the desired position. After the reversed bias DC motor current is applied, the voltage is gradually increased to zero so that the actuator mechanism (20) stops at the desired position as shown by the final value of the actuator position (58) in FIG. 2.
A typical equation showing the actuator position feedback compensator is shown below which includes the DC motor (14) and actuator mechanism (20) momentum calculation which results in a actuator position feedback signal (26).
E.sub.co =G.sub.PWM A.sub.po +G.sub.e e.sub.o -M.sub.t O.sub.o
A po =The actual current cable intervention angular position as measured from the actuator position sensor (21).
A p1 =A po measured 1 millisecond prior in time.
D po =Actuator position command signal (4).
e o =D po -A po =current position error.
O o =A po -A p1 =current timed displacement.
E co =Actuator position feedback signal (26).
G e =Error gain (experimentally determined--separate value for moving into intervention and moving out of intervention).
M t =Timed momentum gain (separate value for moving into intervention and moving out of intervention).
G PWM =Pulse Width Modulated Signal Gain (separate value for moving into intervention and moving out of intervention).
FIG. 3 shows the throttle actuator control system (2) identical to that shown in FIG. 1 except that a second control feedback loop (37) has been added where a throttle valve position sensor (34) is added to the actuator output cable (30) feeding a valve position sensor output (36) into a second feedback loop with a valve position limit feedback block (38) which calculates the maximum position of the actuator mechanism (20) relative to a throttle zero position reference (39) to prevent excessive intervention excursion of the actuator. If the actuator moves in an attempt to close the throttle valve (33) beyond its closing point, the accelerator throttle cable (18) or the output actuator output cable (30) can become slack which is not functionally significant but undesirable. The valve position limited feedback signal (40) is fed to the input summing junction (6) and subtracted from the actuator position command signal (4) to prevent the actuator mechanism (20) from moving further than required for idle throttle position.
The result of the second feedback loop (37) to prevent excursion of the device into the excessive intervention zone (64) and is illustrated by FIG. 4 where the throttle position (60) is shown on the ordinate and versus the accelerator pedal position (62) on the abscissa. The excessive intervention zone (64) is in the area that would mechanically require the throttle position (60) to be lower than fully closed to maintain a no slack cable condition which corresponds to various pedal positions (62) or depending on the extent of travel of the actuator mechanism (20). Line 66 of FIG. 4 illustrates the relationship between the throttle position (60) and the pedal position (62) when the actuator is in a standard position so that full travel of the accelerator pedal (16) results in full travel of the throttle valve (33) allowing full airflow into the engine. Line 68 illustrates the throttle position (60) relationship to accelerator pedal position (62) when the actuator mechanism (20) has traveled to approximately 20% of its travel and results in a 20% decrease in engine throttle valve (33) position for a given accelerator pedal position (62) and the throttle valve (33) maximum opening is limited to 80% of its full travel capability. Likewise, line 70 illustrates the relationship between pedal position (62) and throttle position (60) when the actuator mechanism (20) has traveled to approximately 40% of its travel and the throttle valve (33) maximum opening is limited to 60% of its full travel capability. Line 72 illustrates in a similar fashion the relationship between accelerator pedal (62) and throttle position (60) when the actuator mechanism (20) has traveled to approximately 60% of its potential travel and the throttle valve (33) maximum opening is limited to 40% of its full travel capability.
Thus, referring to line 70 of FIG. 4, if the pedal is either reduced in position while the actuator mechanism (20) remains stationary, the throttle position can be at a minimum and the attempt to further reduce throttle position results in a slack accelerator throttle cable (18) or a slack actuator output cable (30) which is undesirable from an operational standpoint. As explained supra, the high gain valve position limit feedback (38) prevents operation in the excess intervention zone (64) from occurring by subtracting the output of the high gain valve position limit feedback (30) at the input summing junction (6) from the actuator position command signal (4).
FIG. 5 shows an alternate embodiment of the throttle actuator control system (2) where the system input is now a throttle valve position limit signal (42) which is generated by the traction control algorithm software in the vehicle electronic control unit. The throttle valve position limit signal (42) is routed to the input summing junction (6) afterwhich the summing junction output (8) is inputted to the signal power servo amplifier (10) which in turn generates a power amplifier output (12) which is inputted to DC motor (14) and drives the actuator mechanism (20) to the extent and in direction corresponding to the amplifier output (12). The actuator mechanism (20) moves so as to subtract from the input from the accelerator pedal (16) through accelerator pedal cable (18) which results in movement of a actuator output cable (30) which is attached to the throttle plate (33) which resides in a throttle assembly (32). The position output of the actuator output cable (30) is sensed by the throttle valve position sensor (34) where the valve position sensor output (36) is routed to a valve position feedback compensator (46) whose function is to mathematically manipulate the output of the throttle valve position sensor so as to limit the operation of the actuator control mechanism (20) so that the throttle valve (33) does not open beyond the throttle valve position limit signal (42) as commanded by the throttle plate position limit signal (42). This is accomplished as shown in FIG. 5 by subtracting the valve position feedback signal (48) from the throttle valve position limit command signal (42) at the input summing junction (6).
Thus, FIG. 5 illustrates a schematic of a throttle actuator control system (41) which serves to control the maximum position of throttle plate (33) so as to reduce engine power when required by the traction control system when the vehicle is in certain operational modes. This differs from the throttle actuator control system disclosed in FIG. 1 and FIG. 3 where the traction control algorithm in the electronic control unit generates the actuator position command signal (4) rather than the maximum throttle plate position.
The vehicle electronic control unit generates a throttle plate position limit signal (42) which is added at the input summing junction (6) whose output (8) is an input to the signal amplifier (10) whose output (12) powers the DC motor (14) whose mechanical mechanism output (20) is subtracted from the accelerator cable (18) travel. The throttle plate (33) position is measured by throttle valve position sensor (34) where the valve position sensor output (36) is inputted to the valve position feedback compensator (46) where the valve position output (36) is mathematically manipulated to yield a valve position feedback compensator signal (48) that is routed to and subtracted from the throttle valve position limit signal (42). In this manner, the position of the engine throttle valve (33) is controlled to the position command from the traction control program.
FIG. 6 illustrates an alternate embodiment of the present invention where the second feedback loop (39) based on throttle valve position is added to the system schematically shown in FIG. 5. The function of this second feedback loop is to stabilize the position of the actuator through a actuator position feedback control loop similar to that disclosed in FIG. 1. In a like manner to that described supra, the position of the actuator mechanism (20) is measured by a actuator position sensor (21) whose output (22) is routed to a actuator feedback compensator (24) where its value mathematically manipulated so as to generate a actuator position feedback signal (26) which is subtracted from the summing junction output (8) in a second input summing junction (7) where it is then routed to the signal power amplifier (10) in a like manner to that described in previous figures. In this manner, further utilization of the actuator is effectuated while still limiting the opening of the throttle valve (33) for control of the maximum engine power.
FIG. 7 is a schematic view of another embodiment of the present invention similar to that disclosed in FIG. 3. In FIG. 7 a specific embodiment of a throttle actuator (60) is shown where the actuator (60) is driven by a DC motor (14) through a gear reduction drive gearing (61) which turns a lead screw (62). The lead screw (62) is mated to a fulcrum member (64) which transversely moves along the lead screw (62) by engaging threads. The fulcrum member (64) includes a fulcrum level pivot upon which is mounted a lever arm (66) which is free to move rotationally about the fulcrum lever pivot (68) so that movement of the accelerator pedal (16) and the accelerator throttle cable (18) results in a rotation of the lever arm (66) about the fulcrum lever pivot (68) whose position relative to the accelerator throttle cable (18) is determined by the position of the fulcrum member (64) as it follows the threads of the lead screw (62). Rotation of the lever arm (66) determines the axial travel of the actuator output cable (30) which in turn is attached to/and opens the throttle valve (33) residing in the throttle assembly (32).
As the lead screw (62) is rotated by the DC motor (14) in a direction to move the fulcrum member (64) toward the accelerator throttle cable (18), the mechanical relationship between the accelerator throttle cable (18) to the servoactuator output cable (30) is changed so that the opening of the throttle valve (33) is inversely proportional to the amount that the fulcrum lever pivot (68) is moved axially toward the accelerator throttle cable (18) assuming a constant accelerator pedal (16) position.
The rotation position of the lead screw (62) is measured by the actuator position sensor (21) whose output is routed into the actuator position dynamic feedback compensator (24) whose output is then routed to the input summing junction (6) and subtracted from the actuator position command signal (4) whose output is then routed to the signal power amplifier (10) which supplies a power signal in a forward or reverse direction by its amplifier output (12) to the DC motor (14). The throttle valve (33) rotational position is measured by the throttle valve position sensor (34) whose output (36) is routed to the valve limit feedback compensator (38) whose output is then conducted to the summing junction (6) and also subtracts from an actuator position command signal (4). As explained supra, the valve position limit feedback (38) prevents the actuator (60) from assuming a position that would result in slack accelerator pedal or actuator cable (18 and 30 respectively).
The description of the embodiments of the present invention as disclosed herein by way of example only. Although embodiments of the present invention are shown which employ analog electronics, the present invention can be equally well implemented using digital electronics with appropriate software. Various modifications and rearrangement of components contemplated without departing from the spirit in the scope of the invention as hereafter claimed.
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A control system for an engine throttle valve actuator uses an actuator position feedback loop with a compensation factor which applies a reverse voltage having an amplitude based on actuator momentum to a DC motor to effectuate an electrical braking action to achieve high speed response with positional accuracy. A separate position limiting feedback loop is used to prevent excessive actuator excursions. The engine throttle valve is controlled to a selected position by using a throttle valve position feedback loop and a compensation factor to provide a feedback signal to a summing junction.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention described herein is a water-saving device designed for installation in the water tank of new or existing flush water closets (toilets).
Shortages of potable water exist in almost every area of the United States, sometimes on a temporary basis caused by a decrease in the normal amount of rainfall, and, in some places such as the Arizona-California area, on a permanent basis, caused by burgeoning population in an area not blessed with very much water to begin with. A significant portion of the supply of potable water is used to flush toilets. Most toilets are equipped with a storage tank, typically containing several gallons of water, almost all of which is used for each flushing of the toilet. It is often unnecessary to utilize the full tank of water to flush the toilet, but few toilets are equipped with means to reduce selectively the amount of water that is used in the individual flush cycle.
2. Description of the Related Art
One simple means of reducing the amount of water used during a toilet flushing cycle is the use of a brick or similar cheap, heavy, bulky article to reduce the amount of water available for a flush. This means of reducing the amount of water used has certain disadvantages. It represents a permanent reduction in water availability, even though there are occasions when a full flush is essential. Further, the brick tends to erode, and the hard particles can damage the outlet closure, whether a ballcock or flapper, and the seat on which it rests. Another disadvantage is that the pressure at the tank outlet diminishes rapidly as the flush progresses, lessening the force of the flush.
Numerous patents have been granted in the field of saving water by reducing the amount of water discharged from a toilet tank. One common characteristic shared by all such inventions is the manipulation of the outlet closure by a mechanism which contacts the outlet closure directly, forcing it downward to shut off the water flow. Some of the mechanism are relatively complicated, involving the use of numerous parts, which tends to make the mechanism fairly expensive. Another characteristic of the inventions is that they appear to be designed to be installed through the front wall of the tank. The trend in toilet design appears to be to locate the flush handle on one of the narrow end walls of the tank.
Further, there appear to be three ways to initiate the full flush and the partial flush. With some devices, the operating handle is always turned in the same direction, and the length of time the handle is held down determines the length of the flush. A second arrangement is to have a two-part handle, where the entire handle is used for a full flush, and a part of the handle for a partial flush, or vice versa. A third arrangement involves turning the handle in one direction for a full flush, and in the opposite direction for a partial flush. This invention utilizes the third type of arrangement.
U.S. Pat. No. 4,032,997 to Phripp et al. discloses several embodiments, some of which employ a partially buoyant float. One embodiment employs a tilted water chamber. All, however, utilize direct contact to close the outlet valve.
U.S. Pat. No. 4,117,556 to Semler discloses a latch-releasable float operated by a two-way handle.
U.S. Pat. No. 4,216,555 to Detjen discloses a weighted float wherein a latch operated by the handle can release the weight or hold it in place.
U.S. Pat. No. 4,328,596 to Renz discloses a magnetic float release operated by the handle.
U.S. Pat. No. 4,391,003 to Talerico et al. discloses an upper float having a downwardly extending body which is released or retained by a two-way handle mechanism.
U.S. Pat. No. 4,624,018 to Kurtz discloses a two-element handle, one of which elements controls a float release latch.
U.S. Pat. No. 4,651,309 to Battle discloses a float, the movement of which appears to be controlled by the position of the operating handle, and the time the handle is held in a given position. (The Abstract is a little hard to fathom, being an incomplete sentence 285 words long.)
German Patent No. DE3140-033 to Kuhm discloses a device wherein a magnet may be released on to a float for premature closure of the outlet.
As mentioned above, all of the foregoing devices operate by urging a mechanical part downward onto a buoyant outlet closure.
SUMMARY OF THE INVENTION
Toilet water tanks are provided with a circular outlet opening at the bottom of the tank. Water flow through the opening is controlled by an outlet closure which can be either a ballcock or a flapper. The underside of a ballcock has a shape which cooperates with the circular outlet opening to close off the gravity flow of water from the tank. The shape of the underside of a ballcock is sometimes a truncated hemisphere, and sometimes a truncated cone but, in either case, the truncation line is lowermost and defines the opening into the buoyancy chamber. The underside of a flapper has a truncated hemispherical shape, which fits within the outlet opening of the tank, and the flapper has a generally disc-shaped flange extending radially which seats on the outlet opening of the tank to close off the gravity flow of water from the tank. Both the ballcock and the flapper are hollow and are open at the bottom. The purpose of the ballcock or flapper being hollow is to allow it to float on the vortex of exiting water when the tank is emptying, but to allow it to fall of its own weight, and close off the tank outlet when there is no longer enough water in the tank to support it.
In this invention, the partial flush is achieved by venting the hollow space inside the ballcock or flapper at a pre-selected time in the flush cycle, thereby making it non-buoyant, and causing it to fall through the water of its own weight and to close the outlet almost instantaneously, without the necessity to force the ballcock or flapper downward by direct mechanical contact.
Henceforth in this specification, only a flapper will be referred to, for the sake of simplicity, but it is understood that the principle of the invention, and the embodiment thereof, can be applied to a ballcock as easily as to a flapper. A ballcock has a metal stem extending upward, which is guided by a passageway in a bracket clamped to the overflow tube above the tank outlet opening. The lifting chain is attached to the upper end of the stem. Venting the ballcock will produce exactly the same result as venting the flapper described in the preferred embodiment of this invention.
It is an object of this invention to save water by providing a low-cost, reliable device for installation in a conventional toilet tank which permits selection of either a full flush or partial flush of the toilet.
It is a further object of this invention to provide a selectable flushing control device which can be easily adjusted for precise control of the amount of water used during a toilet flushing cycle.
It is a further object of this invention to provide a selectable flushing control device which can be installed in all standard toilet tanks.
It is a further object of this invention to provide a selectable toilet flushing device which will not corrode and which is made of wear-resistant materials.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a segmented elevational view of a water closet water tank with the front wall, side wall and bottom partially cut away.
FIG. 2 is a perspective view of the housing and flange nut of this invention and of the operating handle and retaining screw.
FIG. 3 is a plan view of the operating handle and the housing for the flush selection mechanism and the float as assembled, but not showing the tank front wall.
FIG. 4 is a front elevational view of the elements of FIG. 3.
FIG. 5 is a side elevational view of the elements of FIG. 3.
FIG. 6 is a perspective view of the upper shaft of the flush selection mechanism.
FIG. 7 is a perspective view of the lower shaft of the flush selection mechanism.
FIG. 8 is a sectional view taken on line 8, 9, 11--8, 9, 11 of FIG. 5 showing the mechanism as it appears when a partial flush is initiated.
FIG. 9 is a sectional view taken on line 8, 9, 11--8, 9, 11 of FIG. 5 showing the mechanism as it appears when a full flush is initiated.
FIG. 10 is a sectional view taken at line 10--10 of FIG. 4.
FIG. 11 is a sectional view taken at line 8, 9, 11--8, 9, 11 of FIG. 5 showing the mechanism when it is not in a flush cycle.
FIG. 12 is a perspective view of the operating arm, chain and tlapper.
FIG. 13 is an exploded perspective view of the operating mechanism showing all the elements contained within the housing, and showing the back wall of the housing.
FIG. 14 is a cross-section of the flapper of this invention with the air bleed nipple and air bleed tube in place.
FIG. 15 is a perspective view of the float leaf spring.
FIG. 16 is a perspective view of a flapper operating arm for adapting this invention to toilet tanks having the operating handle extending from the end of the tank.
FIG. 17 is a cross-sectional view of the float assembly.
DETAILED DESCRIPTION OF THE INVENTION
A list of materials of which the preferred embodiment of this invention is manufactured appears at the end of this specification.
The general arrangement of the invention is illustrated in FIG. 1. A conventional toilet water tank 11 is shown in part, and front wall 12, side wall 13 and bottom 14 have been partially cut away for illustrative purposes. For clarity, FIG. 1 does not show the conventional water supply pipe, water supply control valve, and the conventional fill float and arm which control the supply of water to tank. Operating handle 15 is fixed to a shaft to be described later which extends through front wall 12 of tank from housing 16. Float 17 has leaf spring 18 (see FIG. 15) which slideably secures float 17 to float stem 19 extending downward from housing 16. A flapper control arm 20, operable by operating handle 15 by means which will be described below, is connected by means of chain 21 to flapper 22. Flapper 22 (see FIG. 14) has a truncated hemispherical lower body 23 which extends downward into outlet opening 24. Flapper flange 25 rests on seat 26 of outlet opening 24, preventing water from flowing from tank 11. Flapper 22 is hollow, upper body 27 and lower body 23 together enclosing a buoyancy chamber 28 which is open at the bottom, as illustrated in FIG. 14. Air bleed tube 29 connects flapper 22 with nipple 87 extending from housing 16. The connection of the air bleed tube 29 to the flapper 22 is in the vicinity of the lifting chain 21 because, when the flapper 22 is lifted by the chain 21, that part of the buoyancy chamber 28 nearest the chain 21 becomes the highest part, and is most suitable for quick venting of the buoyancy chamber 28. The overflow pipe is of the conventional type, comprising a vertical tube 30 open at its top 31, the lower end of tube 30 being fitted into elbow 32 which conducts excess water to the outlet pipe 33 below seat 26. The water level in tank 11 is not illustrated, but before flushing is at or just below the top 31 of overflow tube 30.
The operating mechanism of this invention will now be described with reference initially to FIGS. 2, 3, 4 and 5. A hollow rectangular housing 16 has front wall 34, side wall 35 and bottom wall 36. Housing 16 has rectangular opening 37 in side wall 35, and rectangular opening 38 in bottom wall 36. Square boss 39 extends outwardly from front wall 34 of housing 16. Position wedges 40 (only 3 of 6 being shown in FIG. 2) are affixed to square boss 39 and front wall 34. Threaded boss 41 extends outwardly from square boss 39. Cylindrical passageway 42 extends through bosses 39 and 41 and front wall 34. Housing 16 is mounted to the interior of front wall 12 of toilet tank 11 by inserting square boss 39 through a square opening (not shown) in wall 12, and threading flange 43 nut onto threaded boss 41 until flange nut 43 is tight against the exterior of front wall 12. Position wedges 40 prevent rotation of housing 16 with respect to front wall 12 of tank 11. Housing 16 has pins 128 extending from each corner thereof for the purpose of assembling housing back wall 57 to housing 16.
Upper shaft 44, (see FIGS. 6 and 13) which is cylindrical, has square boss 45 extending from one end 46. Upper shaft 44 is rotatably engaged in passageway 42 with square boss 45 extending externally from the tank front wall 12. Square boss 45 is suitable for cooperative attachment of operating handle 15 which is, of course, on the outside of tank 11, housing 16 being inside tank 11, as illustrated in. Operating handle 15 is retained on square boss 45 by means of screw 47 which is threaded into hole 48 extending inwardly from end surface 49 of upper shaft 44. Arm 50 extends radially from the cylindrical surface 51 of upper shaft 44. Actuating pin 52 is attached to arm 50 and is oriented parallel to the axis of upper shaft 44. Lobe 53 extends radially from cylindrical surface 51 of upper shaft 44 in approximately the same transverse plane as arm 50. Tooth 54 extends radially from cylindrical surface 51 of upper shaft 44 in approximately the same transverse plane as lobe 53 and arm 50. Tooth 54 has contact surface 55 and contact surface 56. Actuating pin 52 extends axially beyond the plane of rotation of arm 50, lobe 53 and tooth 54.
Housing 16 is closed by back wall 57 (see FIG. 13). Circular boss 58 with cylindrical passageway 59 therein extends into housing 16 from back wall 57. Arcuate boss 60 having wall 61 extends inwardly from back wall 57 below circular boss 58. Upper shaft 44 is supported rotatably at end 46 within cylindrical passageway 42. End 62 of upper shaft 44 is supported rotatably within cylindrical passageway 59 in circular boss 58. Back wall 57 has a hole 129 near each corner. Holes 129 cooperate with pins 128 extending from housing 16 to assemble back wall 57 to housing 16. Back wall 57 is held in place by sonic welding of pins 128 to back wall 57.
Swing arm 63 (see FIG. 13) is rotatably suspended by ring 64 from upper shaft 44 at a position between front wall 34 of housing 16 and arm 50, lobe 53 and tooth 54. Swing arm 65 is rotatably suspended by ring 66 from upper shaft 44 at a position between inner end 67 of circular boss 58 and arm 50, lobe 53 and tooth 54.
Lower shaft 68 (see FIGS. 7 and 13) is cylindrical and has male spline member 69 extending from end 70. Extending radially from cylindrical surface 71 of lower shaft 68 are stop 72, pin 73 and tooth 74 which has contact surfaces 75, 76 and 77. End 78 of lower shaft 68 is suspended in eye 79 of swing arm 63 and end 80 of lower shaft 68 is suspended in eye 81 of swing arm 65. End 70 of lower shaft 68 extends through arcuate boss 60 so that male spline member 69 is outside housing 16. The purpose of pin 73 on lower shaft 68 is to insure that upper shaft 44 and lower dhaft 68 will stay in proper rotational relationship to each other. If someone takes the top off the toilet tank and maniulates the operating arm 20, it might be possible to rotate lower shaft 68 until tooth 74 was out of synchronization with tooth 54. Pin 73 will prevent that from occurring, because pin 73 will act on lobe 53 so as to turn upper shaft 44 and, therefore, actuating pin 52 to a position where pin 73 will cause actuating pin 52 to rotate upper shaft 44 when operating arm 20 is moved in the opposite direction; thus, upper shaft 44 and lower shaft 68 will always mesh properly.
Valve body 82 (see FIG. 13) has cylindrical valve chamber 83 extending downward from upper surface 84. Near the bottom of valve body 82, chamber 83 narrows to a small diameter passageway 85. Rectangular boss 86 extends perpendicularly from the side of valve body 82. Boss 86 extends through hole 37 in side wall 35, its shape cooperating with the shape of hole 37 so as to keep valve body 82 in proper orientation. Cylindrical nipple 87 extends outwardly from boss 86. Air bleed passageway 88 extends through nipple 87 and boss 86 and intersects valve chamber 83.
Valve 89 (see FIG. 13) is generally F-shaped. Spaced-apart upper arm 90 and lower arm 91 extend perpendicularly from stem 92. Near the lower end of stem 92, upper groove 93 and lower groove 94 are provided for the retention of upper O-ring 95 and lower O-ring 96 respectively. Orientation pin 97 is attached tangentially to stem 92 in the area of arms 90 and 91, but on the opposite side of stem 92 from said arms. The purpose of orientation pin 97 is to prevent substantial rotation of stem 92, and therefore of arms 90 and 91 within housing 16.
Float stem 19 (see FIGS. 1, 4, 5, 10 and 11) is cylindrical and is generally T-shaped. The upper end of float stem 19 comprises crossarm 98 having hinge pin 99 at one end and stopper pin 100 extending upwardly at the other end. Hinge pin 99 has a cylindrical boss 101 extending from each end thereof. Cylindrical bosses 101 cooperate with holes 102 in front wall 34 and back wall 57 of housing 16. The hole 102 in back wall 57 is not illustrated, but is located directly opposite hole 102 in front wall 34. Stopper 103 is press-fitted to stopper pin 100 by means of a slit (not shown) in the bottom of stopper 103, and extends upwardly from stopper pin 100. Float 17 (see FIG. 17) having an open bottom, the periphery of which is defined by the lower edge of sidewalls 104 and end walls 105, has cylindrical member 106 extending downwardly from the center of top wall 107. Passageway 108 in cylindrical member 106 is larger than the diameter of float stem 19. Leaf spring 18 (see FIG. 15) is fixedly attached to one of the transition walls 109 of float 17. FIGS. 1, 4, 5 and 11 show two projections 110 extending from one of the transition walls 109 of float 17. These projections 110 are formed during manufacture of float 17, and cooperate with holes 111 in leaf spring 18. To assemble leaf spring 18 tightly to float 17, leaf spring 18 is placed on float 17 with projections 110 extending through holes 111 in leaf spring 18, and the projections 110 are then softened and spread over the spring by sonic welding or similar means, the result being retainers 112, as illustrated in FIG. 4, for example. Crossarm 98 lies within housing 16 with stopper 103 normally in contact with, and closing off, small passageway 85 in valve chamber 83 when float 17 is wholly or partially submerged and, therefore, being urged upward by the water in tank 11.
Flapper control arm 20 (see FIG. 12) has female spline 113 in end 114, which is fitted to male spline 69 on lower shaft 68, and affixed thereto by screw 115 and washer 116. End 117 of flapper control arm 20 has eye 118 for the purpose of retaining upper hook 119 of chain 21. Additional eyes 120 and 121 are provided so that the invention can be fitted to toilet water tanks having the outlet opening 24 in different places. Lower hook 122 of chain 21 is inserted through hole 123 in flapper 22 in the conventional manner. Flapper 22 (see FIG. 14) has legs 124 extending outwardly which cooperate rotatably with pins 125 extending from elbow 32 of overflow pipe 30. Flapper 22 is hollow and extends both above and below flange 25. Upper body 27 can have any shape but, in this embodiment, has the shape of a truncated cone with the smaller end upward. Lower body 23 has, in cross-section, the shape of a truncated hemisphere with the smaller diameter downward. There is no bottom surface to lower body 23, so that upper body 27 and lower body 23 together form a hollow chamber with no bottom. Flapper 22 is conventional in all respects but one. The one difference is that a nipple 126 having flange 127 within buoyancy chamber 28 extends outwardly therefrom, providing a bleed air passageway from the buoyancy chamber 28.
A flexible air bleed tube 29 connects nipple 126 in flapper 22 with nipple 87 of valve body 82, thus forming a continuous air passageway from flapper buoyancy chamber 28, through tube 29 and bleed passageway 88 to valve chamber 83.
The operation of the mechanism will now be described. The position of the mechanism "at rest" is illustrated in FIG. 11 which is a cross-section through the plane of operation of the parts which extend radially outward from upper shaft 44 and lower shaft 68. It will be noted that in the "at rest" position, upper O-ring 95 lies above bleed passageway 88 in valve body 82, and lower O-ring 96 lies below bleed pasageway 88. Buoyancy chamber 28 in flapper 22 is thus sealed off, and air cannot escape therefrom when O-rings 95 and 96 are in the position just described.
Referring now to FIG. 9, when a full flush cycle is desired, operating handle 15 is rotated upward so as to turn upper shaft 44 in a clockwise direction, and lobe 53 will engage surface 77 of tooth 74 on lower shaft 68 so as to turn lower shaft 68 counterclockwise. The force exerted by lobe 53 will also tend to urge lower shaft 68 to swing counterclockwise because lower shaft 68 is completely suspended from upper shaft 44 by swing arms 63 and 65. Lower shaft 68 is prevented from swinging around upper shaft 44, however, because end 70 of lower shaft 68 bears against lower end 133 of arcuate boss 60. The result is that lower shaft 68 merely rotates counter-clockwise, and does not move laterally. When lower shaft 68 rotates counter-clockwise, two things happen. One is that flapper operating arm 20 is rotated counter-clockwise, raising flapper 22 in the conventional manner and allowing tank 11 to empty. At the same time, actuating pin 52 has contacted lower arm 91 of valve 89, forcing valve stem 92 downward. The downward motion is not sufficient, however, to cause upper O-ring 95 to move to or below bleed passageway 88. Flapper 22, therefore, remains buoyant, not having been vented, and the toilet goes through a full flush cycle. Float 17 drops when the water level in the tank 11 has lowered sufficiently, and valve chamber 83 becomes open to the tank 11, but bleed passageway 88 remains sealed because of the position of O-rings 95 and 96. Flapper 22 thus remains buoyant and closes the tank outlet 24 only at the end of the full flush cycle.
In a partial flush cycle, the rotational positions of upper shaft 44 and lower shaft 68, and of valve 89 are shown in FIG. 8. Operating handle 15 has been depressed causing upper shaft 44 to rotate counter-clockwise. Actuator pin 52 has contacted upper arm 90 of valve 89 causing it to move upwards, lifting lower O-ring 96 above the intersection of bleed passageway 88 and valve chamber 83, thus allowing air to flow from buoyancy chamber 28 to valve chamber 83. Tooth 54 on upper shaft 44 has wedged in between contact surfaces 75 and 76 of tooth 74 on lower shaft 68, forcing lower shaft 68 to swing around the axis of upper shaft 44 until lower shaft 68 bears against the upper end 134 of arcuate boss 60. This combined swinging and elevating motion lifts flapper operating arm 20 and causes flapper 22 to lift off outlet opening 24, starting a flush cycle. As the water level drops, flapper 22 will remain buoyant until stopper 103 at the end of crossarm 98 of float stem 19 drops away from small passageway 85 at the lower end of valve chamber 83, thus forming a complete passageway for the air in buoyancy chamber 28 of flapper 22 to vent to toilet water tank 11. The timing of that release of air from flapper 22 is determined by the position of float 17 on stem 19. Float 17 is always submerged at the start of a cycle, and will remain submerged until the water level in tank 11 has dropped to a point where float 17 is no longer in contact with the water. At that point, float 17 is prevented from dropping further because crossarm 98 is resting on the bottom wall 36 of housing 16. When float 17 drops and opens the air passageway, buoyancy chamber 28 is vented, and flapper 22 immediately falls, and closes tank outlet 24. It can thus be seen that the position of float 17 on stem 19 controls the time in the flush cycle at which the flush cycle will be terminated. Leaf spring 18 has hole 135 near one end. Hole 135 is of larger diameter than float stem 19 and is so oriented that, when leaf spring 18 is depressed, hole 135 will line up with passageway 106 in float 17 and will allow float 17 to be moved up and down on float stem 19. Releasing leaf 18 spring secures float 17 to stem 19. Moving float 17 up on stem 19 shortens the partial flush cycle, whereas moving float 17 down on stem 19 lengthens the partial flush cycle.
In either flushing mode, full or partial, when operating handle 15 is released, the mechanism will return to the `at rest` position because of the downward force exerted by the weight of flapper 22 pulling on end 117 of operating arm 20.
It should also be noted, with reference to nipple 126 which extends through upper body 27 of flapper 22, that nipple 126 should be located as close as reasonably possible to the lifting eye 123 of flapper 22. That location will provide the quickest and most complete venting of buoyancy chamber 28 because air will then be bled from buoyancy chamber 28 at or near its top when flapper 22 is lifted by chain 21.
A second embodiment of this invention permits the invention to be installed through the end wall of a toilet water tank, as required in some modern water closet designs, rather than through the front wall. It is necessary only to substitute the L-shaped flapper control arm 140 of FIG. 16 for the flapper control arm 20 of the previously described embodiment. Flapper control arm 140 has a short attachment arm 141 which is at right angles to the lifting arm 142. There is a female spline 143 in attachment arm 141, and an eye 144 at the free end of lifting arm 142 for insertion of upper hook 119 of chain 21. Additional eyes 145 and 146 are provided to allow for different models of water tank 11. Flapper control arm 140 is installed with attachment arm 141 extending horizontally in the opposite direction from operating handle 15.
While it should be recognized that this invention could be manufactured of any of a wide variety of materials and still operate satisfactorily, the preferred embodiment described herein is manufactured of the following materials:
Screws 47 and 115 and washer 116: Chrome-plated steel.
Float 17: Polyethylene.
Leaf spring 18 and chain 21: Stainless steel.
Flapper 22, stopper 103 and O-rings 95 and 96: Neoprene.
Air bleed tube 29: Latex.
Valve 89: Acetal 279 nylon.
Flange nut 43, housing 16, swing arms 63 and 65, upper shaft 44, lower shaft 68, flapper control arm 20, float stem 19, nipple 126 and housing back wall 57: Acetal 270 nylon.
While this invention is susceptible of embodiment in different forms, the drawings and the specification illustrate the preferred embodiment of the invention, with the understanding that the present disclosure is to be considered an exemplification of the principles of the invention, and the disclosure is not intended to limit the invention to the particular embodiment described.
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A buoyant outlet closure, or `flapper` in the preferred embodiment, is vented at a selectively predetermined time in the water closet flushing cycle, causing the flapper to become non-buoyant and to drop and to close the tank outlet, effecting a premature termination of the flushing cycle, and saving the volume of water remaining in the tank. The venting is controlled by turning the externally mounted operating handle in one direction. When the operating handle is turned in the opposite direction, essentially all the water is discharged from the tank, effecting a full flush cycle.
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This application claims the benefit of Provisional application No. 60/106,352, filed Oct. 30, 1998.
BACKGROUND OF THE INVENTION
This Application is a 371 of PCT/US99/05821 filed Mar. 18, 1999, which claims priority to Provisional Application No. 60/106,352 filed Oct. 30, 1998.
This invention is directed to a disk drive device; more specifically, it is directed to a disk drive device which has the characteristic that data can be sent and received to and from a computer through a PCMCIA port.
Various types of disk drive devices that read and write information on a rotating disk medium have been developed and used for some time as computer data storage devices. Widely used magnetic disk drive devices are generally available in two broad categories—removable and fixed. In particular, removable cartridge disk drives read and write information magnetically on a disk that is enclosed in a removable protective case. By contrast, fixed disk drives read and write information magnetically on a fixed disk that is permanently fixed in the data storage device.
Fixed disk drives are used as the principal data storage devices of computers, since they typically have data transmission speeds and storage capacities that are several orders of magnitude greater than removable disk drives. Obviously however, fixed disk drives have the drawback, as compared with removable disk drives, that the disk cannot be easily moved to another computer. As a result, it is ordinarily desirable to provide computers with both a removable disk drive along with a fixed disk drive and most desktop computers have both.
In recent years, however, mobile computers of very small sizes, such as handheld, notebook and lap-top computers, have become widely used. Because space in these computers is a premium, removable cartridge disk drives are attached externally or not at all. Furthermore, in such small computers, external removable cartridge drives are very inconvenient for mobile use. Hence, many of these types of computers do not have disk drives, but rather use IC card based storage media via a PCMCIA port on the computer. However, since IC cards use semiconductor memories, storage capacities are small, and costs are high. These drawbacks have made it difficult for such computers to use programs and data that have large storage requirements.
Therefore, there is a need to provide a disk drive device that is portable and that can be easily attached to and detached from computers in the manner of as IC card.
SUMMARY OF THE INVENTION
In order to meet the aforementioned need, this invention provides a disk drive device of the type that accepts a removable disk cartridge. The disk drive device comprises a spindle motor for rotating, a disk medium within the disk cartridge; a head arm; a read/write head coupled to the head arm for writing and reading information on the disk medium, a head moving means, which operates the head arm; and a control circuit board on which electronic parts are mounted; a protective case which is formed from an upper case and a lower case, the protective case having a form such that it can be inserted into and removed from the PCMCIA port of a computer; and an input/output connector placed on one end of the protective case in order to connect it with a PCMCIA connector when it is inserted into the aforementioned PCMCIA board. In the disk drive device, the spindle motor is coupled to the protective case. Preferably, the bearings of the spindle motor are also coupled to the protective case.
The protective case is preferably formed from a sheet material, preferably by pressing. An attachment hole is placed in the bottom surface of the protective case for attachment of the bearings. To that end, projecting parts with a length almost equal to the thickness of the protective case are formed in the bearings, and the projecting part is inserted into the attachment hole in order to fix the bearings to the protective case. The attachment hole may have a flange attached to the bottom surface of the protective case around the attachment hole. Preferably, the flange is formed by burring the protective case.
The bearings are preferably formed from an oil-containing sintered alloy. Moreover, the bearings are preferably fixed to the protective case by inserting them into the attachment hole under pressure.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing summary, as well as the following detailed description of the preferred embodiments, are better understood when they are read in conjunction with the appended drawings. The drawings illustrate preferred embodiments of the invention to illustrate aspects of the invention. However, the invention should not be considered to be limited to the specific embodiments that are illustrated and disclosed. In the drawings:
FIG. 1 is a perspective view of a disk drive device and a disk cartridge of this invention;
FIG. 2 is an exploded perspective view of the disk drive device of FIG. 1;
FIG. 3 is a cross-sectional view of the disk drive device of FIG. 1 with a cartridge mounted therein;
FIG. 4 is a cross-sectional view of an embodiment of a spindle for use in the disk drive device of FIG. 1; and
FIG. 5 is a cross-sectional view of a second embodiment of a spindle for use in the disk drive device of FIG. 1 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The invention provides a removable cartridge disk drive for use in a PCMCIA form factor. Throughout the description, the invention is described in connection with a removable media disk drive, and the drive is shown having a rotary actuator. Moreover, a disk cartridge is shown with particular dimensions and a particular shape. However, the particular disk drive and cartridge shown only illustrate the operation of the present invention and are not intended as limitations. The invention is equally applicable to other disk drives including linear actuator disk drives and removable media disk drives that accept differently sized and shaped cartridges. Accordingly, the invention should not be limited to the particular drive or cartridge embodiment shown as the invention contemplates the application to other drive and cartridge types and configurations.
FIG. 1 is a perspective drawing of a disk drive device 10 and a disk cartridge 20 . Disk drive device 10 has a protective case 13 , consisting of an upper case 11 and a lower case 12 , which form an interior space for accepting disk cartridge 20 . Upper case 11 and lower case 12 are formed, preferably by pressing or stamping, from sheet material, preferably metal material. Lower case 12 has a bottom surface and side surfaces, and upper case 11 is formed so that it covers the top of lower case 12 .
Upper case 11 has a raised surface 11 a , which projects upward across a width W of the upper case 11 . Width W of this raised surface 11 a is between about 48 mm and 51 mm. Furthermore, lower case 12 also has a raised surface (not shown) similar to raised surface 11 a of upper case 11 . Here, however, the raised surface projects downward. Together the raised surfaces in upper and lower cases 11 and 12 form an interior space in the protective case 13 . Accordingly, space is available within case 13 to accommodate a disk cartridge 20 as well as a disk drive mechanism and electronics.
A plastic frame 14 is placed on the left and right sides of the protective case 13 such that it is sandwiched between upper and lower cases 11 and 12 (see also FIG. 2 ). Preferably, plastic frame 14 is molded to become integrated with the lower case 12 such as by outsert molding. Moreover, the plastic frame 14 is directly exposed at the four corners of the protective case 13 and protects the edges of the upper and lower cases 11 and 12 from impacts and the like.
A connector 15 (shown in phantom) is provided in one end of protective case 13 . The external dimensions of the protective case 13 are in a form which conforms to the PCMCIA Type II standard. According the standard, the form factor should conform to a length of about 85.6 mm, a width of about 54 mm, and a thickness of about 5 mm. By conforming to this standard, drive device 10 can be inserted into a PCMCIA port, such as the type commonly found in computers (not shown). Furthermore, when disk drive device 10 is inserted into a PCMCIA port of a computer in the direction shown by the arrow A, connector 15 connects to a corresponding connector within the PCMCIA port such that current source and electrical signals can be transmitted and received between disk drive device 10 and the computer.
A disk opening 16 for accepting disk cartridge 20 is formed in the other end of the protective case 13 from the connector 15 .
Disk cartridge 20 comprises an outer shell in which a flexible disk 21 is rotatably disposed. A disk access opening 22 is formed in a front portion of disk cartridge 20 to provide access to flexible disk 21 . A shutter 23 is rotatably disposed in cartridge 20 to selectively cover and expose disk access opening 22 . Shutter 23 rotates in a circumferential direction (arrow C) with the center of rotation 24 proximate the center of flexible disk 21 . Disk cartridge 20 is inserted into disk drive device 10 through the disk opening 16 . During insertion, shutter 23 is opened by a shutter opening and closing mechanism, not shown in the drawing, exposing flexible disk 21 for access by a pair of read/write heads, discussed in further detail below.
FIG. 2 illustrates the internal structure of the disk drive device 10 . A control circuit board 16 , containing the disk drive electronics, is firmly adhered to lower case 12 . Connector 15 is fixed to the control circuit board 16 by conventional means such as soldering a lead terminal 15 a of connector 15 to circuit board 16 . Two openings 16 a , 16 b are formed in control circuit board 16 . Opening 16 a is formed to provide access to the lower case 12 for attachment of a spindle motor, which comprises a rotor 40 and a stator coil 41 . Similarly, opening 16 b is formed in order to provide access to lower case 12 for attachment of head arm assembly 30 . Head arm assembly 30 comprises a rotating shaft 31 , two head arms 32 , and a voice coil 33 . A magnetic head (not shown) is fixed to the end of each of the two head arms 32 . Moreover, voice coil 33 is formed on head assembly 30 opposite the head arms 32 . In combination with a magnet (not shown) voice coil 33 constitutes a voice coil motor for rotating the head arm assembly over the flexible disk 21 during drive 10 operation.
When the disk cartridge 20 is inserted into disk drive device 10 , flexible disk 21 couples with a chuck platform 44 which is provided on rotor 40 by the chucking mechanism explained below, and accordingly rotates together with the rotation of rotor 40 . Head arm assembly 30 is retracts during insertion or ejection of disk cartridge 20 . Head arm assembly 30 loads the read/write heads (not shown) after cartridge 10 is inserted and flexible disk 21 is rotating at an operational speed.
FIG. 3 illustrates the various components that are attached to lower case 12 . In the exemplary drive shown in FIG. 3, the components are primarily attached to the lower case 12 . Accordingly, the material thickness of the lower case 12 is preferably greater than that of the upper case 11 . However, the material thickness of the upper and lower case is about 0.2 mm.
A chuck platform 44 is fixed to the top center of the rotor 40 . A circular rotor magnet 46 is coupled to the inside side walls of rotor 40 . The center of chuck platform 44 is center about the center of spindle 43 . Rotor 40 , chuck platform 44 , and spindle 43 all rotate together as one unit. A stator coil 41 is arranged on the bottom surface 12 a of the lower case 12 and opposite rotor magnet 46 . Spindle 43 is fixed to the bottom surface 12 a of lower case 12 through a bearing 42 , so that spindle 43 is free to rotate.
A metal hub 25 is fixed to the center of flexible disk 21 , which is contained in disk cartridge 20 . A ring-shaped projection 25 a is formed in the center of the hub 25 and such that it aligns concentrically with chuck platform 44 . A ring shaped concave groove 44 a is defined in the top surface of chuck platform 44 . A chucking magnet 45 is disposed on the chuck platform to magnetically couple the chuck platform with hub 25 . Furthermore, when disk cartridge 20 is inserted into the disk drive device 10 , ring shaped projection 25 a engages with the ring-shaped concave groove 44 a , and as a result, flexible disk 21 is positioned concentrically with spindle 23 . Positioning is performed in the circumferential direction by the magnetic attraction of the hub 25 by the chucking magnet 45 and the alignment of projection 25 a with groove 44 a.
Control circuit board 16 is adhered to the bottom surface of lower case 12 through an extremely thin insulating film. Upper case flange 13 a and lower case flange 13 b are formed on the ends of the upper and lower cases 11 and 12 . Connector 15 is sandwiched between flanges 13 a , 13 b . Upper and lower case flanges 13 a and 13 b are, respectively, on a lower level than the top surface of upper case 11 and a higher level than the bottom surface of the lower case 12 . Control circuit board 16 is contained in the lower level of lower case 13 . As noted above, connector 15 is connected to circuit board 16 via lead terminal 15 a.
FIGS. 4 and 5 illustrate the attachment of spindle 43 within disk drive device 10 . FIG. 4 shows a first embodiment of the attachment mechanism of spindle 43 , and FIG. 5 shows a second embodiment of the attachment mechanism of spindle 43 . Both embodiments are described below.
As shown in FIG. 4, a flange 12 b is formed on the lower case 12 . Preferably the flange is formed by burring. A bushing 42 , which is preferably formed from an oil-containing sintered metal; is fixed to lower case 12 by pushing it into flange 12 b . A ball bearing 47 is fixed between spindle 43 and bushing 42 to allow spindle 43 to freely rotate. Ball bearing 47 comprises an outer liner 47 a , an inner liner 47 b , and balls 47 c . Spindle 43 is held in place by the force exerted in the thrust direction from the inner liner 47 b , the balls 47 c , and the outer liner 47 a , which are held by bushing 42 .
FIG. 5 shows a second embodiment of the spindle attachment mechanism. The difference between the attachment mechanism of the spindle 43 in the embodiment shown in FIG. 5 from the embodiment of FIG. 4 is that no flange 12 b is formed in lower case 12 . Rather, a concave engaging part 42 a is formed in bushing 42 . Bushing 42 is fixed in place on the lower case 12 by pressing it into an opening formed in lower case 12 .
Other variations on the embodiments discussed above are possible. For example, spindle 43 could be fixed, not to lower case 12 , but to a separate sub-chassis from the lower case 12 through a bushing. The sub-chassis could then be fixed to the lower case 12 . The sub-chassis and lower case 12 could be fixed together by welding.
The above description of preferred embodiments is not intended to impliedly limit the scope of protection of the following claims. Thus, for example, except where they are expressly so limited, the following claims are not limited to applications involving disk drive systems conforming to the PCMCIA standard.
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A disk drive device includes a protective case having an upper case and a lower case. The disk drive device has a form such that the disk drive device can be inserted into and removed from a PCMCIA port of a computer. The disk drive device has an output connector located at one end of the protective case so that the input/output connector can connect with a PCMCIA connector of the computer when the disk drive device is inserted in the PCMCIA port. Information from the computer can thus be stored on the disk drive device, or information from the disk drive device can be read into the computer.
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FIELD OF THE INVENTION
[0001] The present invention relates generally to a contact lens storage case containing silver based the inorganic antimicrobial agent for inhibiting acanthamoeba keratitis due to the putting on and off of the contact lens.
BACKGROUND OF THE INVENTION
[0002] It is well known in the art that there are many different types of the contact lens including a soft contact lens, rigid contact lens, and color contact lens for fashion. Now, it is reported in Japan that almost 16 million people wear contact lenses. Further, the prescribed wearing period of the contacts may be ranged from a day to a few years.
[0003] It is reported in many European and American countries from about 1974 that the corneal infection due to acanthamoeba had been occurred among contact lens wearers, and now the mechanism of acanthamoeba keratitis is evident.
[0004] Acanthamoeba is a genus of amoebae, one of the most common protozoa in soil, and also frequently found in fresh water and in river, lake, and pound or other habitats. Acanthamoeba ingests microorganisms as nutrient and proliferated. Upon number of microorganisms are reduced, it takes a form of cyst to halt the proliferation. Further getting worse the environment, it will die.
[0005] The contact lens of soft type is made of a material higher in its ability to hold water so that the lenses are apt to be contaminated by the deposition and colonization of acanthamoeba.
[0006] In this connection, it is believed that the risk factors associated with acanthamoeba keratitis are higher in the soft contact lens wearer.
[0007] The majority of the soft contact lens wearers are prescribed some type of frequent replacement schedule. With a true daily wear disposable schedule, a brand new pair of lenses is used each day. However, actually, they may be worn continuously after the prescribed schedule had expired (for example 4 or 5 days or more).
[0008] After removed the contact lenses, they are immersed within tap water or multipurpose solution (referred herein below to as MPS) within the lens storage case. When it is intended to put them on, they are picked up from the case.
[0009] When the lenses are handled by fingers and hands contaminated by any bacteria or acanthamoeba, the surface of the lenses and the solution within the case may also be contaminated. In this connection, the lenses stored in the case will further be contaminated.
[0010] The infection has been associated with penetrating corneal trauma. The main cause of the infection is to wear the contaminated contact lenses. The basic countermeasures to be taken for preventing the infection are to handle the lens sterilely and appropriately.
[0011] Although the bacteria and acanthamoeba can easily be killed by thermal disinfection, the heat energy required for the disinfection will distort the lens to destroy the function thereof.
[0012] Organic bacteriocides such as alcoholic, halogenic, and phenolic bacteriocides or antimicrobial agents have toxicity to the cells of the eyes so that using such bacteriocidal additives in MPS may be problematic and cannot be put into practical use. Although the MPS including polyvalent cationic chelate has been proposed (see patent 1 listed hereinbelow), this MPS does not have sufficient effect for killing on acanthamoeba with the predetermined short period.
[0013] Today, we have no sovereign remedy against corneal infection due to acanthamoeba, and it is very difficult to treat it.
[0014] [patent 1] Japanese Laid Open Public Disclosure 2005-177515
DISCLOSURE OF THE INVENTION
Problem or Problems to be Solved by the Invention
[0015] It is the object of the present invention is to provide a contact lens storage case higher in its safety, and being able to inhibit the proliferation of acanthamoeba deposited on the contact lens, and thus to avoid the corneal infection due to acanthamoeba can be avoided.
[0016] The inventor of the present invention find that the concentration of silver content of the resinous material of the contact lens case is not less than 0.005 wt %, microorganism and acanthamoeba will be killed or lost their activity.
The Effect or Effects to be Obtained from the Invention
[0017] The silver based inorganic antimicrobial agent is higher in its safety, have broad antibiotic spectrum, have no drug resistance, and has a long lasing effectiveness.
[0018] The silver based inorganic antimicrobial agent can be produced by carrying silver based compounds on inorganic carriers.
[0019] Suitable inorganic carriers can be selected from the group comprising zeolite, water soluble glass, zirconium phosphate, silica gel, and activated charcoal or so. The silver based compounds to be carried can be produced by the combination of AgNO 3 , Ag 2 O, AgClO 4 , AgCH 3 OO, etc. However, these combinations of silver based inorganic antimicrobial agent are not intended to be exhaustive. Further, the amount of silver content is not limited to the above mentioned percentage.
[0020] Many goods such as cutting boards, fiber products such as closings, and miscellaneous goods including silver based inorganic antimicrobial agent are prevailed in the market places. Of course, the safety thereof had been ascertained.
[0021] The case of the present invention has a function to kill or make cyst the microorganisms and acanthamoeba included in the MPS in the case.
DETAILED DESCRIPTION OF THE INVENTION
[0022] The contact lens storage container of the present invention includes a case body 1 , a pair of storage chambers 2 , 3 provided in the upper part of the case body 1 for containing left and right contact lenses independently therein, and a pair of screw caps 4 , 5 providing lids for removably closing each chamber.
[0023] Elements of the container such as body 1 and screw caps 4 , 5 are all made of synthetic resin. The body 1 is formed by the resinous material containing silver based inorganic antimicrobial agent.
[0024] The caps 4 , 5 may also be made of the material the same as that of the body.
[0025] The amount of the silver based inorganic antimicrobial agent to be added to the resinous material forming the body of the case is controlled to achieve the concentration of the silver content not less than 0.005 wt % with respect to the resin.
[0026] An experiment is carried out as mentioned below to certify whether sufficient acanthamoebacidal property can be derived from the amount of silver content specified above.
Test 1
[0027] Formed are experimental sample cases of polypropylene in which phosphoric antimicrobial agent including silver content in the concentration of 0.5 wt % is added in the concentration of 0.5 wt %, 1.0 wt %, 1.5 wt %, 2.0 wt %, 3.0 wt %, and 5.0 wt % respectively.
[0028] The silver content concentration in the resinous material of each sample is amounted to 0.0025 wt %, 0.005 wt %, 0.0075 wt %, 0.01 wt %, 0.015 wt %, and 0.025 wt % respectively.
[0029] At first the chambers of each case are filled with tap water of 4 ml, then E. coil (IF03972) solution of 0.1 ml controlled to 1.2×10 6 /ml is added thereto, and at the same time the solution of acanthamoeba castellani (ATCC30011) of 0.1 ml controlled to 5.3×10 4 /ml is also added, and thus obtained specimens are left under the condition of 25° C. for 6 hours. The culture medium to be employed can be obtained from Becton, Dickinson and Company as Difco•NB medium (nutrient Broth medium). Measured are the initial bacterial count and the bacterial count after 6 hours had expired.
[0030] The measurement of the number of acanthamoeba will be effected by adding 3% hydrogen peroxide of 5 ml to the solution and leave it for 30 minutes, and filtered thus obtained solution through membrane filter neutralized by natrium pyruvate. Then the filter is incubated in PYG (protease peptone, yeast extract, glucose) medium for 2 weeks. The presence of acanthamoeba is then observed through naked eyes and microscope.
[0000]
TABLE 1
bacterial
bacterial count of
amount of Ag
count of
E. coil after
the presence
(wt %)
of E. coil (/ml)
6 hours (/ml)
of acanthamoeba
0.0025
3 × 10 4
2.3 × 10 4
detected (+)
0.005
3 × 10 4
1.8 × 10 2
detected (±)
0.0075
3 × 10 4
less then 10
undetected
0.01
3 × 10 4
less then 10
undetected
0.015
3 × 10 4
less then 10
undetected
0.025
3 × 10 4
less then 10
undetected
[0031] As can be seen from the test results as listed on the table 1, when the amount of Ag included in the resinous material forming the case body 1 is above 0.005 wt %, substantially no acanthamoeba can be detected, and if it is above 0.0075 wt %, much better effect can be obtained.
Test 2
[0032] Sample cases are formed from polypropylene including antimicrobial agent containing silver zeolite in the amount of 0.25 wt %, 0.5 wt %, 0.75 wt %, 1.0 wt %, 2 wt %, 3 wt %, and 5 wt %. The concentration of Ag of each sample case is amounted respectively to 0.0025 wt %, 0.005 wt %, 0.0075 wt %, 0.01 wt %, 0.02 wt %, 0.03 wt %, and 0.05 wt %.
[0033] The chambers of each sample case are filled with the Rohto C Cube Soft one moist (name of the product) MPS available from Rohto Pharmaceutical Co., Ltd. of 4 ml, then S. aureus (IF 012732) solution of 0.1 ml controlled to 1.5×10 6 /ml is added thereto, and at the same time the solution of acanthamoeba castellani (ATCC30011) of 0.1 ml controlled to 5.3×10 4 /ml is also added, and thus obtained specimens are left under the condition of 25° C. for 6 hours. The culture medium to be employed for S. aureus can be obtained as Difco•NB medium (neutrient Broth medium). Measured are the initial bacterial count and the bacterial count after 6 hours had expired.
[0034] The measurement of the number of acanthamoeba will be effected by adding 3% hydrogen peroxide of 5 ml to the solution and leave it for 30 minutes, and filtered thus obtained solution through membrane filter neutralized by natrium pyruvate. Then the filter is incubated in PYG (protease peptone, yeast extract, glucose) medium for 2 weeks. The presence of acanthamoeba is then observed through naked eyes and microscope.
[0000]
TABLE 2
amount
Ag bacterial
of
of S. aureus
count of bacterial count of
the presence
(wt %)
(/ml)
s. aureus after 6 hours (/ml)
of acanthamoeba
0.0025
3.8 × 10 4
3.2 × 10 4
detected (+)
0.05
3.8 × 10 4
5.8 × 10 2
detected (±)
0.0075
3.8 × 10 4
less then 10
undetected
0.01
3.8 × 10 4
less then 10
undetected
0.02
3.8 × 10 4
less then 10
undetected
0.03
3.8 × 10 4
less then 10
undetected
0.05
3.8 × 10 4
less then 10
undetected
[0035] As can be seen from the test results as listed on the table 2, when the amount of Ag included in the resinous material forming the case body 1 is above 0.005 wt %, substantially no acanthamoeba can be detected, and if it is above 0.0075 wt %, much better effect can be obtained.
Test 3
[0036] The amount of Ag content to be eluted from sample cases of the same lot is measured by means of the atomic absorption spectrophotometer (Z-2310 of Hitachi). The sample cases are formed of resinous material including phosphoric antimicrobial agent containing Ag content in the concentration of 0.5 wt %. The measurement is effected in the condition mentioned hereinbelow.
[0037] The chambers of each case are filled with tap water of 4 ml and left it in 20° C. for 5 hours, and then replaced with new tap water. This procedure is repeated in 10 times. The concentration of eluted Ag in the 1st, 3rd, 5th, 7th, and 10th specimens are measured.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] Embodiments of the present invention will now be described more fully with reference to the accompanying drawings in which:
[0039] FIG. 1 is a cross-sectional view illustrating the contact lens storage case of an embodiment of the present invention;
[0040] FIG. 2 is a cross-sectional view illustrating the contact lens storage case of another embodiment of the present invention; and
[0041] FIG. 3 is a cross-sectional view illustrating the contact lens storage case of yet another embodiment of the present invention.
[0000]
TABLE 3
1st
3rd
5th
7th
10th
amount of
specimen
specimen
specimen
specimen
specimen
Ag (wt %)
(ppb)
(ppb)
(ppb)
(ppb)
(ppb)
0.0025
0
0
1
0
1
0.005
15
14
15
17
18
0.0075
18
21
27
29
31
0.01
19
22
25
33
40
0.015
40
44
58
60
71
0.025
96
135
154
165
170
[0042] It can be appreciated the test results as listed on the table 3 that the sufficient amount of silver ion for preventing the proliferation of acanthamoeba can be eluted from the silver-based inorganic antimicrobial agent included in the resinous material of the lens case to the tap water contained in the chambers of the lens case when the amount of Ag content is not less than 0.005 wt %.
[0043] It can be seen from the experimental results obtained as outlined above that sufficient amount of silver ions are eluted from the silver based inorganic antimicrobic agent included in the case body 1 to the tap water or MPS contained in the storage chambers 2 , 3 , and thus eluted silver ions has enough effects to kill acanthamoeba deposited on the surface of the lenses or freed from the lenses.
[0044] Although the above mentioned experiments are made on the cases in which the silver based inorganic antimicrobic agent is blended over whole mass of the material of the case body, it is not necessary to do so. In other words, the silver based inorganic antimicrobic agent may be included only on the inner surface of the chamber 2 , 3 i.e. the antimicrobic agent can only be included at least in a portion of the resin of the body on which the tap water or preservative solution such as MPS contacts.
[0045] To say concretely on the latter embodiment, the case body 6 may comprise upper and lower layers or formations 7 and 8 as shown in FIG. 2 . In this construction the lower layer 8 does not include any special agents, and the silver based inorganic antimicrobic agent may only be included in the upper layer 7 forming a pair of chambers 9 and 10 .
[0046] In such an embodiment, the total amount of the silver based inorganic antimicrobic agent can be reduced since only the upper layer 7 can include the agent.
[0047] If it is intended to provide caps 11 and 12 in which the material thereof can include the silver based inorganic antimicrobic agent, the caps may also be formed as two-layer structure in which only the layer to be contacted with the preserving liquid in the chamber is provided with the antimicrobic agent.
[0048] The case body and the caps may be of multi layered structure including two or more layered structures. Further, only the surfaces of the case body and the caps may include the silver based inorganic antimicrobic agent.
[0049] The layer including silver based inorganic antimicrobic agent, i.e. the upper layer 7 in the above-mentioned embodiment, may be provided only on the inner surfaces of the chamber 9 , 10 as shown in FIG. 3 , or on the upper surface of the case body 6 . In such cases, it is preferable to provide a sheet material of the thickness about 100 μm impregnated with the silver based inorganic antimicrobic agent and fuse or bond it on the lower layer 8 .
[0050] In this embodiment the amount of the silver based inorganic antimicrobic agent to be utilized can be reduced substantially relative to that of the embodiment as shown in FIG. 2 . The management of the material to be used can be made easily in the manufacture of the lens case. The upper layer 7 can be made replaceable. Thus, the amount of silver contents to be eluted into the tap water or MPS filling the chambers 9 and 10 can be maintained relatively high in spite of the fact that the amount of silver content eluted is reduced with time by replacing the depleted one with bland new one.
[0051] It is to be appreciated that the invention has been described hereinabove with reference to certain examples or embodiments of the invention but that various additions, deletions, alterations and modifications may be made to those examples and embodiments without departing from the intended sprit and scope of the invention. For example, any element or attribute of one embodiment or example may be incorporated into or used with another embodiment or example, unless to do so would render the embodiment or example unpatentable or unsuited for its intended use. All reasonable additions, deletions, modifications and alterations are to be considered equivalents of the described examples and embodiments and are to be included within the scope of the following claims.
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A contact lens storage case comprising a case body including a pair of chambers for containing contact lenses therein, and a pair of lids for closing and opening the chambers, wherein inner faces of the chambers of the case body are formed by a synthetic resin including a silver based inorganic antimicrobic agent comprising a silver based compound carried on an inorganic carrier selected from the group consisting of a zeolite, a water soluble glass, zirconium phosphate, silica gel and activated charcoal. The contact lens storage case inhibits acanthamoeba.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of and claims the benefit of U.S. patent application Ser. No. 11/066,927 entitled, “Device for post-installation in-situ barrier creation and method of use thereof,” filed on Feb. 25, 2005 in the United States Patent and Trademark Office.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable.
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to a device for post-installation in-situ barrier creation, and more particularly to a multi-layered device providing a medium for post-installation injection of remedial substances such as waterproofing resins or cements, insecticides, mold preventatives, rust retardants and the like.
It is common in underground structures, such as tunnels, mines and large buildings with subterranean foundations, to require that the structures be watertight. Thus, it is essential to prevent groundwater from contacting the porous portions of structures or joints, which are typically of concrete. It is also essential to remove water present in the voids of such concrete as such water may swell during low temperatures and fracture the concrete or may contact ferrous portions of the structure, resulting in oxidation and material degradation. Therefore, devices have been developed for removing water from the concrete structure and for preventing water from contacting the concrete structure.
Attempts at removing groundwater from the concrete structure have included a permeable liner and an absorbent sheet. Both absorb adjacent water, carrying it from the concrete structure. This type is system is limited, however, because it cannot introduce a fluid or gaseous substance to the concrete and as the water removed is only that in contact with the system. Additionally, this system does not provide a waterproof barrier.
Among attempts at preventing water from contacting the concrete structure has been the installation of a waterproof liner between a shoring system and the concrete form. This method fails if the waterproof liner is punctured with rebar or other sharp objects, which is common at construction sites. In such an occurrence, it may be necessary for the concrete form to be disassembled so a new waterproof liner may be installed. Such deconstruction is time consuming and expensive. It would therefore be preferable to install a system that provides a secondary waterproof alternative, should the initial waterproof layer fail. Additionally, attempts at preventing water from contacting a concrete structure have included installation of a membrane that swells upon contact with water. While this type of membrane is effective in absorbing the water and expanding to form a water barrier, this type of membrane is limited in its swelling capacity. Therefore, it would be preferable to provide a system that is unlimited in its swelling capacity by allowing a material to be added until the leak is repaired.
Another attempt to resolving this problem was disclosed in “Achieving Dry Stations and Tunnels with Flexible Waterproofing Membranes,” published by Egger, et al. on Mar. 2, 2004 discloses a flexible membrane for waterproofing tunnels and underground structures. The flexible membrane includes first and second layers, which are installed separately. The first layer is a nonwoven polypropylene geotextile, which serves as a cushion against the pressure applied during the placement of the final lining where the membrane is pushed hard against the sub-strata. The first layer also transports water to the pipes at the membrane toe in an open system. The second layer is commonly a polyvinyl chloride (PVC) membrane or a modified polyethylene (PE) membrane, and is installed on top of the first layer. The waterproof membrane is subdivided into sections by welding water barriers to the membrane at their base. Leakage is detected through pipes running from the waterproof membrane to the face of the concrete lining. The pipes are placed at high and low points of each subdivided section. If leakage is detected, a low viscosity grout can be injected through the lower laying pipes. However the welding and the separate installation of the first and second layers make this waterproof system difficult to install, thus requiring highly skilled laborers.
It would therefore be advantageous to provide an in-situ multi-layered device for post-installation concrete sealing, and more particularly a providing a medium for post-installation injection of waterproofing resin.
BRIEF SUMMARY OF THE INVENTION
One object of the invention is to provide a single application which includes a first layer providing an initial waterproof surface. Another object of the invention is to provide a secondary, remedial layer that is operable should the first layer fail. A further object of the invention is to provide that such multi-layer system be quickly and easily installed. An additional object of the present invention allows selective introduction of a fluid substance to specific areas of a structure.
Accordingly, it is an object of the present invention to provide a dual-layered layer that:
has a waterproof layer providing a first level of protection from water penetration; has a second, remedial protection from water penetration through delivering a fluid substance to a structure; allows the introduction of a fluid substance in situ; allows selective introduction of a fluid substance to specific areas of a structure; fixable to a variety of surfaces; and easily and quickly installable.
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 DRAWINGS
FIG. 1 is a cross sectional view of the preferred embodiment of fluid delivery system.
FIG. 2 is an isometric view of fluid delivery system with interlinking extension.
FIG. 3 is a front view of a plurality of fluid delivery systems installed onto a shoring system.
FIG. 4 is a side view of fluid delivery system installed between rebar matrix and shoring system.
FIG. 5 is a side view of fluid delivery system installed between concrete structure and shoring system.
FIG. 6 is an isometric view of compartmentalized fluid delivery system with fluid dispensing mechanisms attached.
DESCRIPTION OF THE INVENTION
FIG. 1 depicts the preferred embodiment of substance delivery system 100 . Substance delivery system 100 is a multi-layer system for delivering substances to a structure, in situ, wherein the multi-layer system has at least two layers. In the preferred embodiment, substance delivery system 100 consists of three conjoined layers: first layer 130 , intermediate layer 120 , and second layer 110 , and at least one piping 150 (shown in FIG. 6 ). While the preferred embodiment of the invention consists of three layers joined together, alternate multiple-layer configurations are possible.
First layer 130 is preferably semi-permeable. In the preferred embodiment of the invention, first layer 130 should be made of a material suitable for permeating fluids therethrough, while prohibiting passage of concrete or other similar structural construction materials. A polypropylene or polyethylene non-woven geotextile is suitable. Additionally, other materials known in the art may be preferable depending on the particular application.
Second layer 110 is a non-permeable layer that is preferably waterproof and self-sealing. Second layer 110 can be an asphalt sheet, or other like material known in the art. Second layer 110 may have an adhesive affixed to second layer interior side 114 , second layer exterior side 112 , or both sides 112 and 114 . Adhesive on second layer interior side 114 permits joining of adjacent panels of substance delivery system 100 . Adhesive on second layer exterior side 112 aids in affixing substance delivery system 100 to shoring system 20 (seen in FIGS. 4 and 5 ).
Intermediate layer 120 is a void-inducing layer, conducive to permitting a free-flowing substance to flow throughout substance delivery system 100 . Intermediate layer 120 may be formed by an open lattice of fibers of sufficient rigidity to maintain the presence of the void when an inward force is exerted against substance delivery system 100 . A polypropylene lattice or other similarly rigid material is preferable. The presence of intermediate layer 120 permits the channeling of free-flowing substances through substance delivery system 100 . Intermediate layer 120 either channels water away from structural construction material 200 , or provides a medium for transporting a free-flowing substance to structural construction material 200 .
Referring to FIG. 2 , second layer 110 , intermediate layer 120 , and first layer 130 are fixedly attached, with intermediate layer 120 interposed between second layer 110 and first layer 130 . Second layer 110 , intermediate layer 120 , and first layer 130 are each defined by a plurality of sides, respectively forming second layer perimeter 116 , intermediate layer perimeter 122 , and first layer perimeter 132 . In the preferred embodiment, intermediate layer perimeter 122 and first layer perimeter 132 are dimensionally proportional, such that permeable layer perimeter 122 and semi-permeable layer perimeter 132 are equivalently sized. Intermediate layer 120 and first layer 130 have a first width that extends horizontally across the layers. Second layer perimeter 116 is partially proportional to intermediate layer perimeter 122 and first layer perimeter 132 , such that at least two sides of second layer perimeter 116 are equivalently sized to the corresponding sides of intermediate layer perimeter 122 and first layer perimeter 132 . Second layer 110 has a second width that extends horizontally across second layer 110 . The second width of second layer 110 is greater than the first width of intermediate layer 120 and first layer 130 . Thus, referring to FIGS. 2 and 3 , when the bottom edges of first layer 130 , intermediate layer 120 , and second layer 110 are aligned, a second layer extension 114 E outwardly extends an extension distance 115 from at least one side of first layer 130 and intermediate layer 120 . Second layer extension 114 E provides an underlay for installing substance delivery system 100 thereupon, thereby eliminating potential weakness at the splice where panels of substance delivery system 100 abut.
In the preferred embodiment, seen in FIGS. 4 and 5 , shoring system 20 is installed to retain earth 10 when a large quantity of soil is excavated. Shoring system 20 includes common shoring techniques such as I-beams with pilings and shotcrete. Substance delivery system 100 is fixedly attached to shoring system exterior surface 22 . As previously discussed, substance delivery system 100 can be attached to shoring system exterior surface 22 by applying an adhesive to second layer exterior side 112 and affixing second layer exterior side 112 to shoring system exterior surface 22 . Alternatively, substance delivery system 100 can be attached to shoring system exterior surface 22 by driving nails, or other similar attachment means, through substance delivery system 100 and into shoring system 20 . In the preferred embodiment second layer 110 is self-sealing. Thus, puncturing second layer 110 with a plurality of nails will negligibly affect second layer's 110 ability to provide a waterproof barrier.
Referring to FIGS. 3 and 6 , substance delivery system 100 canvases shoring system exterior surface 22 . Substance delivery system 100 can be cut to any size, depending on the application. If a single substance delivery system 100 does not cover the desired area, a plurality of panels of substance delivery system 100 are used in concert to provide waterproof protection. As previously discussed, substance delivery system 100 may include second layer extension 114 E for reinforcement at the abutment between adjacent panels of substance delivery system 100 . Thus, a first panel of substance delivery system 100 is fixedly attached to shoring system exterior surface 22 , with second layer extension 114 E extending outwardly onto shoring system exterior surface 22 . A second panel of substance delivery system 100 overlays second layer extension 114 E of the first panel of substance delivery system 100 , thereby interlinking the first and second panels of substance delivery system 100 . This process is repeated until the plurality of panels of substance delivery system 100 blanket shoring system exterior surface 22 . The area of overlap between to adjacent panels of substance delivery system 100 preferably extends vertically. The upper terminal end of substance delivery system 100 , proximate the upper edge of the constructed form (not shown), is sealed with sealing mechanism 105 . Sealing mechanism 105 prevents the injected fluid from being discharged through the top of substance delivery system 100 . Sealing mechanism 105 may be a clamp or other similar clenching device for sealing the upper terminal end of substance delivery system 100 .
Referring to FIG. 6 , division strip 162 is fixedly attached in a vertical orientation between the junction points of adjacent substance delivery systems 100 . In the preferred embodiment division strip 162 has an adhesive surface, thereby allowing division strip 162 to be quickly and safely installed. Alternatively, division strip 162 may be installed by driving a plurality of nails, or similar attaching means, through division strip 162 . Second layer extension 114 E may be of such width as to accommodate division strip 162 and still pein it joining to an adjacent panel of substance delivery system 100 .
Division strip 162 is preferably comprised of a material that swells upon contact with water. When water interacts with division strip 162 , division strip 162 outwardly expands, thereby eliminating communication between the abutting substance delivery systems 100 . Thus, division strip 162 compartmentalizes each panel of substance delivery system 100 . Compartmentalization enables selective injection of a fluid or gas into a predetermined panel of substance delivery system 100 . Alternatively, division strip 162 is formed from a non-swelling material. When division strip 162 is non-swelling, the structural construction material 200 forms around division strip 162 , thereby filling in any voids and forming a seal between adjacent substance delivery systems 100 .
Referring to FIGS. 4 and 6 , at least one piping 150 is engagedly attached to a panel of substance delivery system 100 . Piping 150 is tubular, with inlet 152 , outlet 154 , and cylinder 156 extending therebetween. A plurality of teeth (not shown) outwardly extend from outlet 154 , and engage first layer 130 as to permit injection of fluid into first layer 130 through to intermediate layer 120 . Cylinder 156 extends through rebar matrix 210 , with inlet 152 terminating exterior the structural construction material form (not shown). Cylinder 156 can be secured to rebar matrix 210 through ties, clamps, or other similar means of attachment. The number of piping 150 necessary is dependent on the size of chamber 160 . In the preferred embodiment of the invention, piping 150 should be positioned at lower point 164 , mid point 166 , and upper point 168 .
In the preferred embodiment depicted in FIG. 4 , a structural construction material 200 is inserted into form (not shown). The structural construction material 200 can be concrete, plaster, stoneware, cinderblock, brick, wood, plastic, foam or other similar synthetic or natural materials known in the art. Second layer 110 of substance delivery system 100 provides the primary waterproof defense. If it is determined that second layer 110 has been punctured or has failed, resulting in water leaking to structural construction material 200 , a free flowing substance can be pumped to the panel of substance delivery system 100 located proximate the leak. The free flowing substance is introduced to such panel of substance delivery system 100 via piping 150 in an upward progression, wherein the free flowing substance is controllably introduced to lower point 164 of panel of substance delivery system 100 , then to mid point 166 of panel of substance delivery system 100 , and then to upper point 168 of panel of substance delivery system 100 . A dye may be added to the free flowing substance, allowing for a visual determination of when to cease pumping the free flowing substance to panel of substance delivery system 100 . When the dye in the free flowing substance leaks out of structural construction material 200 , thereby indicating that the selected substance delivery system 100 is fully impregnated, pumping is ceased.
First layer 130 permeates the free flowing substance into the space between first layer 130 and structural construction material 200 . When the free flowing substance is a hydrophilic liquid, the free flowing substance interacts with any water present, thereby causing the free flowing substance to expand and become impermeable, creating an impenetrable waterproof layer. Thus, a secondary waterproof barrier can be created if a failure occurs in second layer 110 .
Alternatively, different free flowing substances may be introduced to substance delivery system 100 , depending on the situation. If the integrity of structural construction material 200 is compromised, a resin for strengthening structural construction material 200 can be injected into substance delivery system 100 to repair structural construction material 200 . Alternatively, a gas may be injected into substance delivery system 100 for providing mold protection, rust retardation, delivering an insecticide, or other similar purposes.
In a separate and distinct embodiment of the invention, intermediate layer 120 may be completely replaced with first layer 130 .
In a separate and distinct embodiment of the invention, substance delivery system 100 is directly attached to the earth, such as in a tunnel or mine. In this embodiment, substance delivery system 100 is inversely installed on a tunnel surface. First layer 130 faces a first tunnel surface and the second layer 110 inwardly faces a second tunnel space. Substance delivery system 100 can be fixedly attached by applying an adhesive to first layer 130 , driving nails through substance delivery system 100 , or similar attaching means known in the art. Substance delivery system 100 is installed in vertical segments, similar to the method described above for the preferred embodiment. However, the plurality of piping 150 is not necessary in the alternative embodiment.
Once substance delivery system 100 is installed on the first tunnel surface, the structural construction material 200 can be installed directly onto second layer 110 .
In the alternative embodiment (not shown) should a failure occur in substance delivery system 100 , an operator can drill a plurality of holes through the structural construction material 200 , ceasing when second layer 110 is penetrated. Such holes would provide fluid access to intermediate layer 120 . A fluid substance (not shown) would then be pumped through the holes, thereby introducing the fluid substance to intermediate member 120 . Intermediate layer 120 channels the fluid substance throughout substance delivery system 100 , ultimately permitting first layer 130 to permeate the fluid substance therethrough.
The foregoing description of the invention illustrates a preferred embodiment thereof. Various changes may be made in the details of the illustrated construction within the scope of the appended claims without departing from the true spirit of the invention. The present invention should only be limited by the claims and their equivalents.
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The present invention relates to a device for post-installation in-situ barrier creation. A multi-layered device provides a medium for of remedial substances such as waterproofing resins or cements, insecticides, mold preventatives, rust retardants and the like. The multi-layer device preferably consists of three conjoined layers: first layer, intermediate layer, and second layer, and at least one piping. The first layer is preferably semi-permeable; the second layer is a non-permeable layer; the intermediate layer is a void-inducing layer. The second layer, intermediate layer, and first layer are fixedly attached, with the intermediate layer interposed between the second layer and the first layer. The multi-layered device is fixedly attached to shoring system exterior surface. At least one piping is engagedly attached to a panel of the multi-layered device. A structural construction material is constructed exterior the multi-layer device. Thereafter, a free flowing substance can be pumped to the multi-layered device.
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TECHNICAL FIELD
This invention relates to a device used to clean barbeque grills.
BACKGROUND OF THE INVENTION
Barbeque grills routinely accumulate charred debris from cooked foods that adhere stubbornly to the grill bars and the intervening grooves. And these are difficult to dislodge and remove. Also, attempting to clean the surfaces with conventional metal brushes lead to the charred debris dropping into the housing of the grill as well as to the floor.
The current invention is designed to overcome the above problems. The cleaner according to this invention is operated only in one direction; thus the debris is likely to fly in only one direction (backwards). Further, the provision of the bristles on a wheel assures that the direction of flight of the debris will be upward, as well as backward. The prong that engages the grill bar at the front end of the cleaner is for efficiently scraping the grill bar surfaces. A further refinement in the invention is the provision of a bag at the top to capture the debris.
The combination of the above components assures efficient cleaning as well as removal of the debris without littering around the grill.
SUMMARY OF THE INVENTION
A grill cleaning device has a handle, a scraper and a rotatable bristled cleaning wheel assembly. The handle has a handle end portion and a cleaning end portion. The scraper projects from the cleaning end portion. The rotatable bristled cleaning wheel assembly has a rotatable axle held in the cleaning end portion. The bristled cleaning wheel is affixed to the axle. The bristled wheel has substantially radially extending cleaning bristles on each of the lateral ends of the cleaning wheel and two sets of opposing laterally extending bristles. Each set of lateral bristles projects inwardly from a wheel rim toward a lateral center of the wheel assembly. The bristles are wire preferably made from stainless steel or another non-corrosive metal. The ends of the laterally extending bristles are spaced from the center of the wheel a distance equal to or slightly less than a grill rod. The radially extending bristles extend from a hub end on each side of the wheel to a distance to contact either support rods of a grill underlying the grill rods or at least below the grill rods.
The grill cleaning device further has a cavity adjacent and behind the cleaning wheel in the cleaning end portion. The cavity holds a debris-holding container. The debris-holding container has an open intake for catching dislodged debris. The debris-holding container can be a folded bag assembly adapted to be stowed inside the cavity and upon unfolding becomes the debris-holding container. The folded bag includes an upper forward pull tab to raise or unfold the bag. The folded bag has a rotatable rear mounted support to hold the bag fixed open during use. The structure further has an external wheel affixed to the rear bag support, the wheel rotatable and pivots the support to move the bag into or out of a folded condition. The bag is fixed to the scraper at a lower forward tab. The upper pull tab has a snap to fit onto a projecting pin on the scraper which also holds the lower tab. The bag can be made of a woven fabric or can be made of a thermoplastic. The bag is preferably detachable for cleaning and can be disposable.
The cleaning wheel assembly rotates counterclockwise upon a rearward pull of the handle. The counterclockwise rotation of the cleaning wheel causes dislodged debris to be directed on either lateral side of the scraper rearwardly and upwardly into the debris-holding container, some portion of the loose debris may fall into the bottom of the grill, most however is captured in the debris-holding container.
The handle portion has a threaded hole and the cleaning end portion has a threaded shaft for securing the two portions. The handle portion further comprises an outer grip sleeve, the grip sleeve fits over the handle.
The grill cleaning device can be manufactured with the debris cleaning end portion being a molded plastic structure, more preferably, a metal structure of aluminum or stainless steel. The scraper is made of steel or another metal. The handle end portion can be wood, plastic or more preferably, a metal structure of aluminum or stainless steel. The handle grip sleeve can be a thin membrane of plastic or elastomeric material.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described by way of example and with reference to the accompanying drawings in which:
FIG. 1 is a perspective view of the grill cleaning device made according to the present invention.
FIG. 2 is a second perspective view looking upwardly at the grill cleaning device from FIG. 1 showing the folded debris-collecting container fully extended and the cleaning wheel assembly and scraper at the cleaning end portion.
FIG. 3 is a third perspective view of the grill cleaning device with the debris-collecting container shown folded in a retracted position.
FIG. 4 is a fourth perspective view similar to FIG. 3 , but with the debris-collecting device fully extended and open.
FIG. 5 is a cross sectional view of the grill cleaning device taken along the longitudinal length of the device.
FIG. 6 is an end cross sectional view taken along the dashed or broken line 6 - 6 from FIG. 5 , the dashed lines of FIG. 6 show an exemplary grill.
FIG. 7 is an end cross sectional view of the folded debris container taken along dashed or broken line 7 - 7 taken from FIG. 5 .
FIG. 8 is a longitudinal cross sectional view similar to FIG. 5 , but with the debris-collecting container fully extended and open.
FIG. 9 is an exploded view of the grill cleaning device made according to the present invention.
FIG. 10 is an exploded view of the bristled cleaning wheel assembly.
FIG. 11 is a view of the grill cleaning device in use.
DETAILED DESCRIPTION OF THE INVENTION
With reference to FIG. 1 , a grill cleaning device 10 is shown. The device 10 has a handle 12 , a scraper 40 and a rotatable bristled cleaning wheel assembly 20 . The device 10 has a handle end portion 12 and a cleaning end portion 14 . The scraper 40 projects from the end of the cleaning end portion 14 . The rotatable cleaning wheel assembly 20 has a rotatable axle held in the cleaning end portion 14 . As illustrated, the device 10 further has a folded debris container 30 . The folded container 30 as illustrated can be a fabric or plastic member that is shown in a collapsed and folded state. An upper forward end tab 36 is shown that is snapped to the scraper assembly 40 using a snap-in fastener 37 .
With reference to FIGS. 2 , 3 and 4 , various perspective views of the assembly are shown. In FIG. 2 , the device 10 is shown with the debris-holding container 30 in a released, fully extended position such that the debris container 30 can receive debris from the wire wheel assembly 20 during the cleaning procedure. With reference to FIG. 3 , another perspective view is shown of the device 10 . In this view the folded debris container 30 is shown secured at the fastener 37 in its folded and retracted condition. In FIG. 4 , the debris container 30 is shown in the same view as FIG. 3 only with the container 30 being in the fully extended and upward position. In this position, the support 32 helps maintain the folded bag in this upright and fully opened position.
With reference to FIG. 5 , a cross sectional view of the device 10 is shown. The handle end portion 12 is shown threadingly engaged onto a shaft 15 of the end cleaning portion 14 . To accomplish this fastening of the two portions, a threaded opening 16 is provided in the handle portion 12 . The handle portion 12 is further shown with an elastomeric sleeve or covering 12 A that surrounds the handle 12 . This elastomeric or plastic sleeve 12 A is provided to give the user a gripping surface upon which to hold the device 10 . As further illustrated, in the cleaning end portion 14 the support 32 is shown horizontal in the stowed position. In dashed lines, this support 32 is rotated vertically in a vertical position when the container 30 is moved to the fully upright and open extended position. The wheel assembly 20 underlies the scraper 40 as illustrated and is held to the end portion 14 via an axle 24 .
With further reference to FIGS. 6 and 10 , the rotatable bristled wheel assembly 20 is illustrated. In FIG. 6 , a cross sectional view of the device 10 cut along line 6 - 6 from FIG. 5 shows the wheel assembly 20 in its mounted condition held securely in the end portion 14 . As shown, with reference to FIGS. 5 and 9 , the axle 24 extends across the wheel assembly 20 into openings 55 on each side of the end portion 14 . This axle 24 is retained by retaining washers 25 that are snapped over the ends of the axle 24 pinning the axle in the end portion 14 as illustrated in FIG. 6 . Inward of the retaining washers 25 and the sides of the end portion 14 are shown radially extending wire wheels 21 . These wire wheels 21 are formed from wire bristles extending radially outwardly. These wire wheels 21 have a center hub 27 . The center hub 27 has a square or rectangular end on each laterally inward side of the wheel 21 . The square hub 27 is adapted to fit into the rims 28 and lock into a square opening 29 on the rim 28 itself, as shown in FIG. 10 . Projecting from the rim 28 are laterally extending wire bristles 23 . These laterally extending wire bristles 23 are directed facing the opposite laterally extending wire bristles 23 on the opposite rim 28 . These rims 28 are fitted into a center hub 26 and are rotatably fixed to the hub 26 in such a fashion that as the wheel assembly 20 rotates, the center hub 26 and both of these rims 28 with laterally extending wire bristles 23 will rotate in a counterclockwise direction as the handle assembly 12 is pulled toward the user. This is best illustrated in FIG. 11 showing the hand 3 of an operator pulling the device 10 backwards along the rods 2 wherein the debris 5 on the rod 2 is then flipped off the rod 2 with the lateral extending wire bristles 23 rotating in such a fashion that the debris 5 is either thrown generally rearwardly and upwardly into the debris-holding container 30 as illustrated through the opening 33 . This debris 5 projects on each side of the scraper 40 . The scraper 40 provides a means to pull any remaining surface debris 5 along the top surface of the rod 2 . The lateral bristles 23 loosen and deflect a large portion of the debris 5 as the wheel assembly 20 rotates. To facilitate rotation, the center hub 26 can be pushed against the rods 2 upon which the hub 26 is riding. This provides additional rolling assistance for the wheel assembly 20 as it is being turned and pulled over the rods 2 cleaning them. The radially extending bristles 21 extend from a hub 27 end on each side of the wheel assembly 20 to a distance to contact either support rods 4 of a grill underlying the grill rods 2 or at least below the grill rods 2 , as shown in FIG. 6 .
With reference to FIG. 7 , the debris container 30 is shown in a folded and retracted position inside a cavity 31 in the end portion 14 . A knob 50 is shown attached to the support 32 of the device 10 such that the wheel 50 can be rotated to move the support 32 from a horizontal stowed position to a vertical position as the bag 30 is being extended into its fully opened position.
With reference to FIG. 8 , this is best shown in the fully open position wherein the container 30 is extended from the cavity 31 in the end portion 14 . With further reference to FIG. 8 , the container 30 is held by snaps 39 , 38 and 37 and snaps 60 , 62 . To remove the container 30 , one simply pulls the snaps open releasing the container 30 . The container 30 can be cleaned or washed or discarded and replaced at the user's option.
With reference to FIG. 9 , an exploded view of the entire device 10 is shown. In this view, the scraper 40 is more clearly shown having a projected end 41 with a scraper surface 42 that extends back to a flanged end 44 . This flanged end 44 has openings to hold snaps or rivets 60 , 62 which can securely hold the scraper 40 into position. Preferably these snaps or rivets 60 , 62 are solidly riveted to the end portion 14 through the openings 57 shown in FIG. 9 . Additionally, the support 32 , formed as two portions held together by fastener 52 , extends through openings 54 on each side of the end portion 14 . The axle 24 of the wheel assembly 20 extends through the openings 55 in this end portion 14 as shown in FIG. 5 . As further shown, the handle 12 is shown in a preferred embodiment with the opening 16 being threaded. The handle 12 being a solid structure having a flexible sleeve 12 A covering it.
It is important that the wire bristles on both the radially extending wheel 21 and laterally extending wires 23 on the rims 28 of the wire wheel assembly 20 be made of a tough durable material, preferably a stainless steel or aluminum material of high stiffness. This will ensure that the wheels 20 when rotating about the rods 2 of the grill cleaning it can provide enough rigidity to break free the debris 5 from the rods 2 of the grill allowing the debris 5 to be removed easily. The cleaning end portion 14 and the handle portion 12 can be made of a lightweight aluminum or stainless steel or other metal material or alternatively can be made of heavy duty fabric material if so desired or the handle alternatively could be made of wood. It is believed that preferably lightweight aluminum assembly provides the most advantageous construction as it provides both corrosion resistance and strength.
The present invention provides a mechanical grill cleaning device 10 that requires no vacuum assist in collecting debris or battery operated rotation of the wheel assembly 20 , although such additions could be used without departing from the inventive concept. It is believed preferable that the entire cleaning can be manually accomplished with the device 10 . One of the main objectives is to keep the surroundings of the grill from being splattered by the charred dislodged debris 5 . It is further important that the debris 5 mainly is captured in the debris container 30 with some residual debris 5 being dropped into the bottom of the grill, but otherwise not allowing the dislodged debris 5 from spraying over the patio deck as is a common problem with conventional grill cleaning.
Variations in the present invention are possible in light of the description of it provided herein. While certain representative embodiments and details have been shown for the purpose of illustrating the subject 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 subject invention. It is, therefore, to be understood that changes can be made in the particular embodiments described, which will be within the full intended scope of the invention as defined by the following appended claims.
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A grill cleaning device has a handle, a scraper and a rotatable bristled cleaning wheel assembly. The handle has a handle end portion and a cleaning end portion. The scraper projects from the cleaning end portion. The rotatable bristled cleaning wheel assembly has a rotatable axle held in the cleaning end portion. The bristled cleaning wheel assembly is affixed to the axle. The bristled wheel assembly has substantially radially extending cleaning bristle wheels on each of the lateral ends of the cleaning wheel assembly and two sets of opposing laterally extending bristles. Each set of lateral bristles projects inwardly from a wheel rim toward a lateral center of the wheel assembly. The bristles are made from sturdy non-rusting metal. The ends of the laterally extending bristles are spaced from the center of the wheel assembly a distance equal to or slightly less than a grill rod.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. Ser. No. 10/819,476, filed on Apr. 4, 2004 and also claims the benefit of U.S. provisional Ser. No. 60/461,499, filed Apr. 9, 2003 since it was claimed in the parent application, U.S. Ser. No. 10/819,476.
BACKGROUND OF THE INVENTION
[0002] This invention concerns ladder stabilizers which act to brace a ladder to prevent falls when a ladder leaned against a wall or other structure slides to either side step ladder also can tip over to either side as when a user shifts his or her weight or leans too far to the side.
[0003] This hazard very commonly causes falls, particularly where a ladder rests on an uneven surface. Numerous ladder stabilizers have been devised to avoid this problem, including mounting telescoping outriggers to each side of a ladder, sloping downwardly from a point of attachment to each ladder stile and having an end engaged with the ground or other supporting surface.
[0004] The problem with these prior outrigger stabilizers is the need to manually carefully adjust the length of each outrigger to securely engage the surface of each situation. This is a time consuming chore and thus is often not done or only done haphazardly.
[0005] Another problem is that the adjusted length is sometimes not well secured or a thumbscrew becomes loose, allowing free telescoping of the outrigger components to occur and this defeats the purpose of the stabilizer. Also, the ladder may shift as the user moves on the ladder which could shift the stabilizer lower end where it may not reach the ground.
[0006] It is important that such a stabilizer be simple, convenient, failsafe, and low in cost to manufacture.
[0007] It is the object of the present invention to provide an outrigger type ladder stabilizer which does not require that manual adjustments be made and is very securely held in each adjusted condition.
SUMMARY OF THE INVENTION
[0008] The above object and others which will become apparent upon a reading of the following specification and claims are achieved by an outrigger stabilizer comprised of a pair of telescoped tubes with an inner tube slidable in an outer tube connected at its upper end to one side of the ladder, extending down laterally therefrom. The two tubes are interconnected with a one way acting brake which allows the inner tube to freely telescope out from the outer tube, but instantly locks to the outer tube when any movement to telescope the inner tube back into the outer tube is attempted. This provides an automatic length adjustment and a secure locking of the stabilizer in each adjusted length. The one way brake comprises an arrangement wherein the upper end of the outer lower tube mounts an inclined annular disc having a hole through which the inner tube is loosely fit. A metal strip fixed to the upper end of the outer tube is formed with an inclined reaction tab which engages the bottom of one side of the annular disc so that it assumes a downwardly inclined orientation as the opposite side of the disc tilts down under its own weight.
[0009] The inclined annular disc acts as a one way acting brake while it allows the outer tube to telescope out from the outer tube but instantly wedges to the inner tube and to lock the two tubes together when forces are exerted on the stabilizer tending to telescope the two tubes back together. The friction between the side of the inner tube and one edge of the disc hole causes a wedging action to instantly occur. The length adjustment occurs automatically by gravity when the ladder is placed against a vertical support and the lower tube descends until the ground or other surface is encountered by its bottom end. At the same time, the locking action is very secure and will not loosen.
[0010] The inner tube may be quickly released to allow telescoping back into the outer tube by lifting up on the tilted down side of the disc.
[0011] The strip may also have an upper tab sloping back inwardly which causes the annular disc to tilt in the opposite direction and prevents escape of the inner tube when the stabilizer is inverted. A disc keeper element can also be provided.
[0012] Any tipping action is positively resisted by attaching an outrigger stabilizer on each side of the ladder.
[0013] An outrigger stabilizer according to the invention can be quickly mounted to each side of the ladder by a cross tube passed through a selected rung hole and each end received in a hole on the upper end of the inner tube, retained therein with an end cap.
[0014] The stabilizer may also be secured to a step ladder by an adjustable clamp mounted to the top of each upper tube and gripping a respective step ladder stile.
DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a pictorial view of an extension ladder having a pair of outrigger stabilizers according to the invention installed thereon and deployed on the adjacent ground surfaces.
[0016] FIG. 1A is a pictorial exploded view of the outrigger stabilizers shown in FIG. 1 , with the extension ladder on which they are installed.
[0017] FIG. 2 is an enlarged partially sectional fragmentary view of the upper end of the telescoped tubes included in the stabilizer shown in FIGS. 1 and 1 A and a one way brake associated therewith.
[0018] FIG. 3 is a pictorial view of the upper end of the telescoped tubes and a second form of the one way brake shown in FIG. 2 , shown rotated towards the viewer.
[0019] FIG. 4 is a pictorial view of the upper end of the outer tube with phantom lines showing a section to be removed in manufacturing an integral reaction tab included in an alternate embodiment of the one way brake.
[0020] FIG. 5 is a pictorial view of a step ladder having an outrigger stabilizer according to another embodiment of the invention installed thereon.
[0021] FIG. 6 is an enlarged exploded pictorial view of the upper end of the outrigger stabilizer and adjacent portions of the stepladder shown in phantom lines.
[0022] FIG. 7 is a sectional view of portions of another embodiment of the invention.
[0023] FIG. 8 is a pictorial view of the upper end of the outer tube shown in FIG. 7 .
[0024] FIG. 9 is a partially sectional and pictorial view of portions of yet another embodiment of the invention.
[0025] FIG. 10 is a sectional view through the lower tube shown in FIG. 9 .
DETAILED DESCRIPTION
[0026] In the following detailed description, certain specific terminology will be employed for the sake of clarity and a particular embodiment described in accordance with the requirements of 35 USC 112, but it is to be understood that the same is not intended to be limiting and should not be so construed inasmuch as the invention is capable of taking many forms and variations within the scope of the appended claims.
[0027] Referring to the drawings, and FIGS. 1-4 , an extension ladder 10 is shown leaning against a building wall 12 , the ladder 10 resting on the adjacent ground surface. A pair of outrigger stabilizers 14 according to the invention each have an attachment at their upper end to the side of a respective ladder stile 16 .
[0028] This attachment is preferably accomplished by installing a cross tube 18 through one of the normally hollow rungs 20 of the ladder 10 at an intermediate height thereon.
[0029] Each outrigger stabilizer 14 extends at an outward angle and rests on the adjacent ground surface so as to provide a bracing of the ladder 10 , resisting any tendency to slide or tip sideways.
[0030] Each outrigger stabilizer 14 automatically adjusts in length to have its lower end brought into secure contact with the ground surface regardless of the unevenness of the ground surface adjacent the ladder 10 .
[0031] This is accomplished by the telescoping out of an inner elongated member comprised of an inner tube 22 slidably received in an outer tube 24 ( FIG. 1A ) thickness as the outer tube 24 drops down from its own weight. These 22, 24 tubes are constructed of metal, such as of steel or aluminum and have a sufficiently heavy wall to provide a sturdy support, able when extended to resist the force exerted by the ladder 10 and if any tendency to tip sideways occurs.
[0032] The inner tube 22 has a flattened tip 25 which has a hole 23 formed therein sized to receive the cross tube 18 . A pair of retainer end caps 19 are installed to keep the same on a respective tube end. The lower end of each outer tube 24 has a nonskid tip 27 installed thereon.
[0033] A one way acting brake 26 is installed on the upper end of the outer tube 24 which allows the inner tube 22 to freely telescope out of the outer tube 24 , as the outer tube 24 drops away under the influence of gravity but instantly engages to rigidly connect together the tubes 24 , 26 to resist any telescoping together of these tubes 22 , 24 if a pushing force is exerted on the upper tube 22 after the outer tube 24 contacts the supporting surface.
[0034] Each one way acting brake 26 comprises an annular disc 28 , preferably of steel which is held at an inclined angle on the upper end of the outer tube by an upwardly and outwardly angled reaction tab 30 formed in a metal strip 32 affixed as by welding or by other means to one side of the upper end of the outer tube 24 . The reaction tab 30 contacts the bottom surface of the left side of the disc 28 when the stabilizer 14 is upright.
[0035] An upwardly and inwardly angled tab 34 may also be formed at the end of the strip 32 , contacting the left side of the disc 28 when the stabilizer 14 is inverted to prevent escape of the inner tube 22 .
[0036] As noted, the hole 29 in the annular disc 28 is sufficiently larger than the inner tube 22 to allow the same to assume the tilted downward orientation shown in FIG. 2 .
[0037] Since the inner tube 22 is held on the cross tube 18 , the outer tube 24 will freely drop down, sliding along the inner tube 22 which is thereby telescoped out of the outer tube 24 . The annular disc 28 assumes a downwardly angled orientation, tilting down to the right as viewed in FIG. 2 , under the influence of gravity and the left side is held up by engagement with the reaction tab 30 . Thus, the friction between the edge of the hole 29 in the annular disc 28 tends to lift and straighten the disc 28 , increasing the clearance between the upper tube 22 and the disc 28 when the inner tube 22 is telescoping out of the outer tube 24 .
[0038] On the other hand, when the inner tube 22 starts to move relatively towards the outer tube 24 to be telescoped thereinto, friction between the inner tube 22 and the edge of the hole in the disc 28 immediately drives the right side of the disc 28 further down to increase the inclination thereof to eliminate the clearance between the hole 29 in the annular disc 28 and create a wedging between inner tube 22 and the disc 28 since the disc 28 is restrained by the reaction tab 30 . This positively prevents the inner tube 22 from moving into the outer tube 24 .
[0039] The reversely angled reaction tab 34 creates the same action if the ladder 10 is angled down as during handling so that the inner tube 22 will be locked and not fall out of the outer tube 24 inadvertently.
[0040] FIG. 3 shows another form of the one way acting brake 26 A. In this version, the strip 32 A is formed only with the outwardly and upwardly angled tab 30 A. A cotter pin 36 is installed in holes through the disc perimeter and the tab 36 to retain the disc 28 . The fit thereon is loose enough to allow reversing of the inclination of the annular disc 28 to capture the inner tube 22 when inverted.
[0041] FIGS. 4A and 4B show an alternate construction in which the upper end of the outer tube 24 has a portion 38 cut away to leave a segment 40 . That segment is formed to create an integral strip 32 B and tabs 30 B and 34 B.
[0042] FIGS. 5 and 6 show the mounting of an outrigger stabilizer 14 mounted to a stepladder 42 by a stile clamp 48 . The clamp 44 comprises a pair of U-shaped pieces 46 , 48 fit together to be slidably adjustable to various sized stiles.
[0043] A slot 50 and a hole 52 receive a screw 54 which also passes through a drilled hole in the ladder stile 56 , with a nut 58 tightened to secure the same in any adjusted position to fit the same to stiles of various widths.
[0044] Thus, a simple but very convenient to use outrigger stabilizer has been provided which is also very reliable in preventing sideways tipping of a ladder to alleviate a major source of ladder accidents.
[0045] In one successful design, the tabs 30 and 34 were about three quarters of an inch long, with about a 20° angle there between. The lower side of the inclined annular disc 28 was located to have about one quarter of an inch clearance with the top edge of the outer tube 24 to insure that contact would not occur and wedging engagement with the inner tube 22 was assured. The outer tube 24 was 57.5 inches long and the inner tube 22 was 60 inches in length to insure that an upper end protruded therefrom when the two tubes were collapsed together.
[0046] FIGS. 7 and 8 show a simplified form of the invention in which an annular disc 60 is not mounted to either outer tube 62 or inner tube 64 . Rather, the annular disc 60 is simply slidably held on the inner tube 64 , with the inside diameter of the annular disc 60 being larger than the outside diameter of the inner tube 64 to allow it to incline as shown sufficiently to create a wedging action to the inner tube 64 when restrained on one side by an elevated crest 66 on the outer tube 62 .
[0047] This crest 66 is created by cutting off the outer tube at an angle as shown. The annular disc 60 thus drivingly engages the lower tube 62 by contact with the crest and is wedged to the inner tube 64 when the inner tube 64 is slid into the outer tube 62 . When the inner tube 62 slides out, no engagement of the disc 60 occurs, with either tube. Thus, a one way brake is provided.
[0048] The crest 66 is preferably formed over and outwardly to create a larger dimension across the outer tube 62 . This prevents the outer tube 62 from entering the inside diameter of the annular disc 60 .
[0049] FIGS. 9 and 10 shows a variation in which the lower tube 62 A is extruded with a series of outside ribs 68 which create a larger dimension across the lower tube 62 A.
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An outrigger stabilizer combined with a ladder includes a telescoped outer tube and inner elongated member with a one way brake freely allowing telescoping movement of the inner member out of the outer tube to automatically adjust to engage the ground but instantly locking together when any collapsing movement is attempted to brace the ladder in any adjusted position.
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CROSS REFERENCE TO RELATED APPLICATIONS
This is a continuation-in-part of U.S. application Ser. No. 12/317,073 filed Dec. 18, 2008 and of U.S. application Ser. No. 11/255,160 filed Oct. 20, 2005 (issued as U.S. Pat. No. 7,484,625 on Feb. 3, 2009), both of which are a continuation-in-part of U.S. application Ser. No. 11/059,584 filed Feb. 16, 2005 (issued as U.S. Pat. No. 7,159,654 on Jan. 9, 2007) which is a continuation-in-part of U.S. application Ser. No. 10/825,590 filed Apr. 15, 2004 (abandoned)—from all (applications and patents) of which the present invention and application claim the benefit of priority under the Patent Laws and all of which are incorporated fully herein in their entirety for all purposes.
BACKGROUND OF THE INVENTION
Field of the Invention
This invention is directed to systems and methods for identifying risers used in wellbore operations; in certain aspects, to risers with wave-energizable identification apparatus thereon; and, in certain aspects to identifying using wave-energizable apparatus such as, but not limited to, radio frequency identification devices or tags.
Description of Related Art
The prior art discloses a variety of systems and methods for using surface acoustic wave tags or radio frequency identification tags in identifying items, including items used in the oil and gas industry such as drill pipe. (See e.g. U.S. Pat. Nos. 4,698,631; 5,142,128; 5,202,680; 5,360,967; 6,333,699; 6,333,700; 6,347,292; 6,480,811; and U.S. patent application Ser. No. 10/323,536 filed Dec. 18, 2002; Ser. No. 09/843,998 filed Apr. 27, 2001; Ser. No. 10/047,436 filed Jan. 14, 2002; Ser. No. 10/261,551 filed Sep. 30, 2002; Ser. No. 10/032,114 filed Dec. 21, 2001; and Ser. No. 10/013,255 filed Nov. 5, 2001; all incorporated fully herein for all purposes.) In many of these systems a radio frequency identification tag or “RFIDT” is used on pipe at such a location either interiorly or exteriorly of a pipe, that the RFIDT is exposed to extreme temperatures and conditions downhole in a wellbore. Often an RFIDT so positioned fails and is of no further use. Also, in many instances, an RFIDT so positioned is subjected to damage above ground due to the rigors of handling and manipulation.
The present inventors have realized that, in certain embodiments, risers can be provided with effective identification apparatus.
BRIEF SUMMARY OF THE PRESENT INVENTION
The present invention discloses, in some aspects, member including: a body, the body having an exterior surface and two spaced-apart ends, wave energizable identification apparatus on the exterior surface of the body, the wave energizable identification apparatus wrapped in fabric material, the fabric material comprising heat-resistant non-conducting material, the wave energizable identification apparatus wrapped and positioned on the body so that the wave energizable identification apparatus does not contact the body, and the member is a riser. The present invention discloses, in some aspects a riser with a riser body having an interior surface, an exterior surface, and two spaced-apart ends; at least one identification assembly (or a plurality of) on the riser body; the identification assembly having an assembly body and a wave energizable apparatus in the body; the assembly body having an interior surface, an exterior surface, and a channel therethrough in which is positioned part of the riser body; the assembly body releasably secured on the riser body; and the wave energizable apparatus positioned within the assembly body.
The present invention discloses, in certain aspects, a riser with a riser body, the body having an exterior surface, two spaced-apart ends; wave-energizable identification apparatus on the exterior surface; the wave-energizable identification apparatus held on the body with holding apparatus which, in one aspect, is a fabric wrap of fabric material, the fabric material including heat-resistant non-conducting material; and the wave-energizable identification apparatus wrapped and positioned so that the wave-energizable identification apparatus does not contact the riser body.
In certain aspects, the present invention discloses such a riser in which the identification apparatus is held in place by a strap that encompasses the riser body.
The present invention, in certain aspects, provides an item, an apparatus, or a tubular, e.g. a piece of drill pipe, with a radio frequency identification tag either affixed exteriorly to the item, apparatus or tubular or in a recess in an end thereof so that the RFIDT is protected from shocks (pressure, impacts, thermal) that may be encountered in a wellbore or during drilling operations. In one particular aspect one or more RFIDT's are covered with heat and/or impact resistant materials on the exterior of an item. In one particular aspect, the present invention discloses systems and methods in which a piece of drill pipe with threaded pin and box ends has one or more circumferential recesses formed in the pin end into which is emplaced one or more radio frequency identification tags each with an integrated circuit and with an antenna encircling the pin end within A recess. The RFIDT (OR RFIDT'S) in a recess is protected by a layer of filler, glue or adhesive, e.g. epoxy material, and/or by a cap ring corresponding to and closing off the recess. Such a cap ring may be made of metal (magnetic; or nonmagnetic, e.g. aluminum, stainless steel, silver, gold, platinum and titanium), plastic, composite, polytetrafluoroethylene, fiberglass, ceramic, and/or cermet. The RFIDT can be, in certain aspects, any known commercially-available read-only or read-write radio frequency identification tag and any suitable known reader system, manual, fixed, and/or automatic may be used to read the RFIDT.
The present invention, in certain aspects, provides an item, apparatus, or tubular, e.g. a piece of drill pipe, with one or more radio frequency identification tags wrapped in heat and impact resistant materials; in one aspect, located in an area 2-3″ in length beginning ½ from the 18 degree taper of the pin and drill pipe tool joint so that the RFIDT (or RFIDT's) is protected from shocks (pressure, impacts, thermal) that may be encountered on a rig, in a wellbore, or during wellbore (e.g. drilling or casing) operations. In one particular aspect, the present invention discloses systems and methods in which a piece of drill pie with threaded pin and box ends has one or more radio frequency identification tags each with an integrated circuit and with an antenna encircling the pin end upset area located exteriorly on the pipe, e.g. in an area ½″-2½ from a pin end 18 degree taper. The RFIDT (or RFIDT's) is protected by wrapping the entire RFIDT and antenna in a heat resistant material wrapped around the circumference of the tube body and held in place by heat resistant glue or adhesive, e.g. epoxy material which encases the RFIDT. This material is covered with a layer of impact resistant material and wrapped with multiple layers of wrapping material such as epoxy bonded wrap material. Preferably this wrapping does not exceed the tool joint OD. The RFIDT can be (as can be any disclosed herein), in certain aspects, any known commercially-available read-only or read-write radio frequency identification tag and any suitable know reader system, manual, fixed, and/or automatic may be used to read the RFIDT. Such installation of RFIDT's can be carried out in the field, in a factory, on a rig, with no machining necessary. Optionally, a metal tag designating a unique serial number of each item, apparatus, or length of drill pipe located under the wrap with the RFIDT(s) insures “Traceability” is never lost due to failure of the RFIDT(s). Replacement of failed RFIDT's can be carried out without leaving a location, eliminating expensive transportation or trucking costs. Optionally the wrap is applied in a distinctive and/or a bright color for easy identification. Determining whether an item, apparatus, or a tubular or a length of drill pipe or a drill pipe string is RFID-tagged or not is visibly noticeable, e.g. from a distance once the RFIDT's are in place.
In certain particular aspects an RFIDT is encased in a ring of protective material whose shape and configuration corresponds to the shape of the pin end's recess and the ring is either permanently or removably positioned in the recess. Such a ring may be used without or in conjunction with an amount of protective material covering the ring or with a cap ring that protectively covers the RFIDT. Two or more RFIDT's may be used in one recess and/or there may be multiple recesses at different levels. In other aspects a ring is provided which is emplaceable around a member, either a generally cylindrical circular member or a member with some other shape.
With an RFIDT located in a pipe's pin end as described herein, upon makeup of a joint including two such pieces of pipe, an RFIDT in one pipe's pin end is completely surrounded by pipe material—including that of a corresponding pipe's box end—and the RFIDT is sealingly protected from access by materials flowing through the pipe and from materials exterior to the pipe. The mass of pipe material surrounding the enclosed RFIDT also protects it from the temperature extremes of materials within and outside of the pipe.
In other aspects [with or without an RFIDT in a recess] sensible material and/or indicia are located within a recess and, in one aspect, transparent material is placed above the material and/or indicia for visual inspection or monitoring; and, in one aspect, such sensible material and/or indicia are in or on a cap ring.
A pipe with a pin end recess as described herein can be a piece of typical pipe in which the recess is formed, e.g. by machining or with laser apparatus or by drilling; or the pipe can be manufactured with the recess formed integrally thereof. In certain particular aspects, in cross-section a recess has a shape that is square, rectangular, triangular, semi-triangular, circular, semi-circular, trapezoid, dovetail, or rhomboid.
It has also been discovered that the location of an RFIDT or RFIDT's according to the present invention can be accomplished in other items, apparatuses, tubulars and generally tubular apparatuses in addition to drill pipe, or in a member, device, or apparatus that has a cross-section area that permits exterior wrapping of RFIDT(s) or circumferential installation of antenna apparatus including, but not limited to, in or on casing, drill collars, (magnetic or nonmagnetic) pipe, thread protectors, centralizers, stabilizers, control line protectors, mills, plugs (including but not limited to cementing plugs), and risers; and in or on other apparatuses, including, but not limited to, whipstocks, tubular handlers, tubular manipulators, tubular rotators, top drives, tongs, spinners, downhole motors, elevators, spiders, powered mouse holes, and pipe handlers, sucker rods, and drill bits (all which can be made of or have portions of magnetizable metal or nonmagnetizable metal).
In certain aspects the present invention discloses a rig with a rig floor having thereon or embedded therein or positioned therebelow a tag reader system which reads RFIDT's in pipe or other apparatus placed on the rig floor above the tag reader system. All of such rig-floor-based reader systems, manually-operated reader systems, and other fixed reader systems useful in methods and systems according to the present invention may be, in certain aspects, in communication with one or more control systems, e.g. computers, computerized systems, consoles, and/or control system located on the rig, on site, and/or remotely from the rig, either via lines and/or cables or wirelessly. Such system can provide identification, inventory, and quality control functions and, in one aspect, are useful to insure that desired tubulars, and only desired tubulars, go downhole and/or that desired apparatus, and only desired apparatus, is used on the rig. In certain aspects one or more RFIDT's is affixed exteriorly of or positioned in a recess an item, apparatus, or tubular, e.g., in one aspect, in a box end of a tubular. In certain aspects antennas of RFIDT's according to the present invention have a diameter between one quarter inch to ten inches and in particular aspects this range is between two inches and four inches. Such systems can also be used with certain RFIDT's to record on a read-write apparatus therein historical information related to current use of an item, apparatus or of a tubular member; e.g., but not limited to, that this particular item, apparatus, or tubular member is being used at this time in this particular location or string, and/or with particular torque applied thereto by this particular apparatus.
In other aspects, a pipe with a pin end recess described therein has emplaced therein or thereon a member or ring with or without an RFIDT and with sensible indicia, e.g., one or a series of signature cuts, etchings, holes, notches, indentations, alpha and/or numeric characters, raised portion(s) and/or voids, filled in or not with filler material (e.g. but not limited to, epoxy material and/or nonmagnetic or magnetic metal, composite, fiberglass, plastic, ceramic and/or cermet), which indicia are visually identifiable and/or can be sensed by sensing systems (including, but not limited to, systems using ultrasonic sensing, eddy current sensing, optical/laser sensing, and/or microwave sensing). Similarly it is within the scope of the present invention to provide a cap ring (or a ring to be emplaced in a recess) as described herein (either for closing off a recess or for attachment to a pin end which has no such recess) with such indicia which can be sensed visually or with sensing equipment.
It is within the scope of this invention to provide an item, apparatus, or tubular member as described herein exteriorly affixed RFIDT(s) and/or with a circular recess as described above with energizable identification apparatus other than or in addition to one or more RFIDT's; including, for example one or more surface acoustic wave tags (“SAW tags”) with its antenna apparatus in the circular apparatus.
Accordingly, the present invention includes features and advantages which are believed to enable it to advance riser identification technology. Characteristics and advantages of the present invention described above and additional features and benefits will be readily apparent to those skilled in the art upon consideration of the following description of embodiments and referring to the accompanying drawings.
Certain embodiments of this invention are not limited to any particular individual feature disclosed here, but include combinations of them distinguished from the prior art in their structures, functions, and/or results achieved. Features of the invention have been broadly described so that the detailed descriptions that follow may be better understood, and in order that the contributions of this invention to the arts may be better appreciated. There are, of course, additional aspects of the invention described below and which may be included in the subject matter of the claims to this invention. Those skilled in the art who have the benefit of this invention, its teachings, and suggestions will appreciate that the conceptions of this disclosure may be used as a creative basis for designing other structures, methods and systems for carrying out and practicing the present invention. The claims of this invention are to be read to include any legally equivalent devices or methods which do not depart from the spirit and scope of the present invention.
What follows are some of, but not all, the objects of this invention. In addition to the specific objects stated below for at least certain preferred embodiments of the invention, other objects and purposes will be readily apparent to one of skill in this art who has the benefit of this invention's teachings and disclosures. It is, therefore, an object of at least certain preferred embodiments of the present invention to provide:
New, useful, unique, efficient, nonobvious devices, risers with apparatus for identification and/or for tracking, inventory and control and, in certain aspects, such risers employing identification device(s), e.g. wave-energizable devices, e.g., one or more radio frequency identification tags and/or one or more SAW tags;
New, useful, unique, efficient, nonobvious devices, systems and methods for apparatus identification, tracking, inventory and control and, in certain aspects, such systems and methods employing identification device(s), e.g. one or more RFIDT and/or one or more SAW tags;
Such systems and methods in which a member is provided with one or more exteriorly affixed RFIDT's and/or one or more recesses into which one or more identification devices are placed;
Such systems and methods in which the member is a cylindrical or tubular member and the recess (or recesses) is a circumferential recess around either or both ends thereof, made or integrally formed therein;
Such systems and methods in which filler material and/or a cap ring is installed permanently or releasably over a recess to close it off and protect identification device(s);
Such systems and methods in which aspects of the present invention are combined in a nonobvious and new manner with existing apparatuses to provide dual redundancy identification;
Such systems and methods in which a sensing-containing member (flexible or rigid) is placed within or on an item; and
Such systems and methods which include a system on, in, or under a rig floor, and/or on equipment, for sensing identification device apparatus according to the present invention.
The present invention recognizes and addresses the problems and needs in this area and provides a solution to those problems and a satisfactory meeting of those needs in its various possible embodiments and equivalents thereof. To one of skill in this art who has the benefits of this invention's realizations, teachings, disclosures, and suggestions, various purposes and advantages will be appreciated from the following description of certain embodiments, given for the purpose of disclosure, when taken in conjunction with the accompanying drawings. The detail in these descriptions is not intended to thwart this patent's object to claim this invention no matter how others may later attempt to disguise it by variations in form, changes, or additions of further improvements.
The Abstract that is part hereof is to enable the U.S. Patent and Trademark Office and the public generally, and scientists, engineers, researchers, and practitioners in the art who are not familiar with patent terms or legal terms of phraseology to determine quickly from a cursory inspection or review the nature and general area of the disclosure of this invention. The Abstract is neither intended to define the invention, which is done by the claims, nor is it intended to be limiting of the scope of the invention or of the claims in any way.
It will be understood that the various embodiments of the present invention may include one, some, or all of the disclosed, described, and/or enumerated improvements and/or technical advantages and/or elements in claims to this invention.
Certain aspects, certain embodiments, and certain preferable features of the invention are set out herein. Any combination of aspects or features shown in any aspect or embodiment can be used except where such aspects or features are mutually exclusive.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
A more particular description of embodiments of the invention briefly summarized above may be had by references to the embodiments which are shown in the drawings which form a part of this specification. These drawings illustrate certain preferred embodiments and are not to be used to improperly limit the scope of the invention which may have other equally effective or legally equivalent embodiments.
FIG. 1A is a perspective view of a pin end of a drill pipe according to the present invention.
FIG. 1B is a perspective views of a pin end of a drill pipe according to the present invention.
FIG. 1C is a partial cross-sectional view of the drill pipe of FIG. 1A .
FIG. 1D shows shapes for recesses according to the present invention.
FIG. 2 is a graphical representation of a prior art commercially-available radio frequency identification tag apparatus.
FIG. 2A is a perspective view of a torus according to the present invention.
FIG. 2B is a side view partially in cross-section, of the torus of FIG. 2B .
FIG. 2C is a top perspective view of a torus according to the present invention.
FIG. 2D is a side view in cross-section of a recess according to the present invention with the torus of FIG. 2C therein.
FIG. 2E is a top view in cross-section of a torus according to the present invention.
FIG. 2F is a top view of a torus according to the present invention.
FIG. 2G is a side view of the torus of FIG. 2F .
FIG. 2H is a side view of a torus according to the present invention.
FIG. 2I is a top view of a cap ring according to the present invention.
FIG. 2J is a side view of the cap ring of FIG. 2I .
FIG. 2K is a top view of a cap ring according to the present invention.
FIG. 2L is a side view of the cap ring of FIG. 2K .
FIG. 2M is a top view of a cap ring according to the present invention.
FIG. 3A is a side view, partially in cross-section, of a tubular according to the present invention.
FIG. 3B is an enlarged view of a box end of the tubular of FIG. 3A .
FIG. 3C is an enlarged view of a pin end of the tubular of FIG. 3A .
FIG. 4A is a side schematic view of a rig according to the present invention.
FIG. 4B is a side view partially in cross-section of a tubular according to the present invention.
FIG. 4C is a schematic view of the system of FIG. 4A .
FIG. 5A is a schematic view of a system according to the present invention.
FIG. 5B is a side view of a tubular according to the present invention.
FIG. 5C is a schematic view of a system according to the present invention.
FIG. 5D is a schematic view of a system according to the present invention.
FIG. 6 is a side view of a tubular according to the present invention.
FIG. 7A is a side view of a tubular according to the present invention.
FIG. 7B is a cross-section view of the tubular of FIG. 7B .
FIG. 8A is a side view of a stabilizer according to the present invention.
FIG. 8B is a cross-section view of the stabilizer of FIG. 8A .
FIG. 8C is a side view of a centralizer according to the present invention.
FIG. 8D is a cross-section view of the centralizer of FIG. 8C .
FIG. 8E is a side view of a centralizer according to the present invention.
FIG. 8F is a cross-section view of the centralizer of FIG. 8E .
FIG. 8G is a side view of a centralizer according to the present invention.
FIG. 8H is a cross-section view of the centralizer of FIG. 8E .
FIG. 9A is a side cross-section view of a thread protector according to the present invention.
FIG. 9B is a side cross-section view of a thread protector according to the present invention.
FIG. 10A is a side cross-section view of a thread protector according to the present invention.
FIG. 10B is a perspective view of a thread protector according to the present invention.
FIG. 11 is a cross-section view of a thread protector according to the present invention.
FIG. 12A is a schematic side view of a drilling rig system according to the present invention.
FIG. 12B is an enlarged view of part of the system of FIG. 12A .
FIG. 13A is a side view of a system according to the present invention.
FIG. 13B is a side view of part of the system of FIG. 13A .
FIG. 14A is a schematic view of a system according to the present invention with a powered mouse hole.
FIG. 14B is a side view of the powered mouse hole of FIG. 14A .
FIG. 14C is a cross-section view of part of the powered mouse hole of FIGS. 14 A and B.
FIG. 14D is a side view of a powered mouse hole tool according to the present invention.
FIG. 15A is a side view of a top drive according to the present invention.
FIG. 15B is an enlarged view of part of the top drive of FIG. 15A .
FIG. 16A is a side cross-section view of a plug according to the present invention.
FIG. 16B is a side cross-section view of a plug according to the present invention.
FIG. 17A is a perspective view of a portable RFIDT bearing ring according to the present invention.
FIG. 17B is a side view of the ring of FIG. 17A .
FIG. 17C is a perspective view of the ring of FIG. 17A with the ring opened.
FIG. 17D is a top view of a ring according to the present invention.
FIG. 17E is a top view of a ring according to the present invention.
FIG. 18A is a side view of a whipstock according to the present invention.
FIG. 18B is a bottom view of the whipstock of FIG. 18A .
FIG. 19 is a side view of a mill according to the present invention.
FIG. 20A is a perspective views of a pipe manipulator according to the present invention.
FIG. 20B is a perspective views of a pipe manipulator according to the present invention.
FIG. 21 is a schematic view of a system according to the present invention.
FIG. 22 is a schematic view of a system according to the present invention.
FIG. 23 is a schematic view of a system according to the present invention.
FIG. 24 is a perspective view of a blowout preventer according to the present invention.
FIG. 25 is a side view of a tubular according to the present invention.
FIG. 26 is an enlargement of part of FIG. 25 .
FIG. 27 is a perspective view of a tubular according to the present invention.
FIG. 28 is a perspective view of a tubular according to the present invention.
FIG. 29 is a perspective view of a tubular according to the present invention.
FIG. 29A is a schematic of part of the tubular of FIG. 29 .
FIG. 30 is a perspective view of a tubular according to the present invention.
FIG. 30A is a perspective view of a tubular according to the present invention.
FIG. 30B is a perspective view of a tubular according to the present invention.
FIG. 31 is a schematic view of a system according to the present invention with a riser with riser sections according to the present invention.
FIG. 32A is a perspective view of a riser according to the present invention.
FIG. 32B is an enlargement of part of the riser of FIG. 32A .
FIG. 33A is a perspective view of an identification assembly for a riser section according to the present invention.
FIG. 33B is a cross-section view of the assembly of FIG. 33A .
FIG. 33C is an enlargement of part of the assembly of FIG. 33A as shown in FIG. 33D .
FIG. 33D is a cross-section view of the assembly of FIG. 33A .
FIG. 33E is a cross-section view of the assembly of FIG. 33D .
FIG. 34A is a cross-section view of a shield according to the present invention.
FIG. 34B is a side view of the shield of FIG. 32A .
FIG. 34C is a bottom view of the shield of FIG. 32A .
FIG. 34D is an end view of the shield of FIG. 32A within a tube.
FIG. 34E is a perspective view of the shield of FIG. 32A .
FIG. 35 shows in cross-section shields according to the present invention.
FIG. 36 shows in cross-section shields according to the present invention.
FIG. 37 is a perspective view of an apparatus according to the present invention.
FIG. 38 is a perspective view of an apparatus according to the present invention.
FIG. 39 is a perspective view of an apparatus according to the present invention.
FIG. 40A is a cross-section view of a riser identification assembly according to the present invention.
FIG. 40B is a cross-section view of a riser identification assembly according to the present invention.
FIG. 40C is a cross-section view of a riser identification assembly according to the present invention.
Certain embodiments of the invention are shown in the above-identified figures and described in detail below. Various aspects and features of embodiments of the invention are described below and some are set out in the dependent claims. Any combination of aspects and/or features described below or shown in the dependent claims can be used except where such aspects and/or features are mutually exclusive. It should be understood that the appended drawings and description herein are of certain embodiments and are not intended to limit the invention or the appended claims. On the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the invention as defined by the appended claims. In showing and describing these embodiments, like or identical reference numerals are used to identify common or similar elements. The figures are not necessarily to scale and certain features and certain views of the figures may be shown exaggerated in scale or in schematic in the interest of clarity and conciseness.
As used herein and throughout all the various portions (and headings) of this patent, the terms “invention”, “present invention” and variations thereof mean one or more embodiments, and are not intended to mean the claimed invention of any particular appended claim(s) or all of the appended claims. Accordingly, the subject or topic of each such reference is not automatically or necessarily part of, or required by, any particular claim(s) merely because of such reference. So long as they are not mutually exclusive or contradictory any aspect or feature or combination of aspects or features of any embodiment disclosed herein may be used in any other embodiment disclosed herein.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1A-1C show a pin end 10 of a drill pipe according to the present invention which has a sealing shoulder 12 and a threaded end portion 14 . A typical flow channel 18 extends through the drill pipe from one end to the other. A recess 20 in the top 16 (as viewed in FIG. 1C ) of the pin end 10 extends around the entire circumference of the top 16 . This recess 20 is shown with a generally rectangular shape, but it is within the scope of this invention to provide a recess with any desired cross-sectional shape, including, but not limited to, the shapes shown in FIG. 1D . In one aspect an entire drill pipe piece with a pin end 10 is like the tubular shown in FIG. 3A or the drill pipe of FIG. 12B . The recess 20 (as is true for any recess of any embodiment disclosed herein) may be at any depth (as viewed in FIG. 1C ) from the end of the pin end and, as shown in FIGS. 1A-1C may, according to the present invention, be located so that no thread is adjacent the recess.
It is within the scope of the present invention to form the recess 20 in a standard piece of drill pipe with a typical machine tool, drill, with a laser apparatus such as a laser cutting apparatus, or with etching apparatus. Alternatively, it is within the scope of the present invention to manufacture a piece of drill pipe (or other tubular) with the recess formed integrally in the pin end (and/or in a box end). The recess as shown in FIG. 1C is about 5 mm wide and 5 mm deep; but it is within the scope of certain embodiments of the present invention to have such a recess that is between 1 mm and 10 mm wide and between 2 mm and 20 mm deep.
A cap ring 22 is installed over the recess 20 which seals the space within the recess 20 . This cap ring 22 (as may be any cap ring of any embodiment herein) may be made of any suitable material, including, but not limited to: metal, aluminum, zinc, brass, bronze, steel, stainless steel, iron, silver, gold, platinum, titanium, aluminum alloys, zinc alloys, or carbon steel; composite; plastic, fiberglass, fiber material such as ARAMID™ fiber material; KEVLAR™ or other similar material; ceramic; or cermet. The cap ring 22 may be sealingly installed using glue, adhesive, and/or welding (e.g., but not limited to Tig, Mig, and resistance welding and laser welding processes).
Disposed within the recess 20 beneath the cap ring 22 , as shown in FIG. 1C , is an RFIDT device 28 which includes a tag 24 and an antenna 26 . The antenna 26 encircles the recess 20 around the pin end's circumference and has two ends, each connected to the tag 24 . The RFIDT tag device may be any suitable known device, including, but not limited to the RFID devices commercially available, as in FIG. 2 , e.g. from MBBS Company of Switzerland, e.g. its E-Units™ (TAGs) devices e.g., as in FIG. 2 . The RFIDT device 28 may be a read-only or a read-write device. It is within the scope of this invention to provide one, two, three or more such devices in a recess 20 (or in any recess of any embodiment herein). Optionally, the RFIDT device (or devices) is eliminated and a recess 20 with a particular varied bottom and/or varied side wall(s) and/or a cap ring with a nonuniform, varied, and/or structured surface or part(s) is used which variation(s) can be sensed and which provide a unique signature for a particular piece of drill pipe (as may be the case for any other embodiment of the present invention). These variations, etc. may be provided by different heights in a recess or different dimensions of projections or protrusions from a recess lower surface or recess side wall surface, by etchings thereon or on a cap ring, by cuts thereon or therein, and/or by a series of notches and/or voids in a recess and/or in a cap ring and/or by sensible indicia. Optionally, instead of the RFIDT device 28 (and for any embodiment herein any RFIDT) a SAW tag may be used and corresponding suitable apparatuses and systems for energizing the SAW tag(s) and reading them.
In certain aspects of the present invention with a recess like the recess 20 as described above, a ring or torus is releasably or permanently installed within the recess with or without a cap ring thereover (like the cap ring 22 ). Such a ring or torus may have one, two, or more (or no) RFIDT's therein. FIGS. 2A and 2B show a torus 30 installable within a recess, like the recess 20 or any recess as in FIG. 1C , which includes a body 31 with a central opening 31 a . An RFIDT 32 is encased on the body 31 . The RFIDT 32 has an integrated circuit 33 and an antenna 34 which encircles the body 31 . In certain aspects the body 31 (as may be any body of any torus or ring according to the present invention) is made of metal, plastic, polytetrafluorethylene, fiberglass, composite, ceramic, or of a nonmagnetizable metal. The opening 31 a (as may be any opening of any torus or ring herein) may be any desired diameter. Optionally, or in addition to the RFIDT device 28 , and RFIDT device 28 a (or devices 28 a ) is affixed exteriorly to the pin end 10 with a multi-layer wrap as described below (see FIGS. 28, 26 ) [any RFIDT(s) or SAW tag(s) may be used for the RFIDT 28 a].
FIGS. 2C and 2D show a torus 35 which has a central opening 35 a , a body 36 and an RFIDT 37 therein with an antenna 38 that encircles the body 36 and an integrated circuit 39 . In one aspect a recess 20 a in a body for receiving a torus 35 has an upper lip 20 b (or inwardly inclined edge or edges as shown in FIG. 2D ) and the body 36 is made of resilient material which is sufficiently flexible that the torus 35 may be pushed into the recess 20 a and releasably held therein without adhesives and without a cap ring, although it is within the scope of the present invention to use adhesive and/or a cap ring with a torus 35 .
FIG. 2E shows a torus 40 according to the present invention with a body 40 a which is insertable into a recess (like the recess 20 , the recess 20 a , or any recess disclosed herein) which has one or more elements 41 therein which serve as strengthening members and/or as members which provide a unique sensible signature for the torus 40 and, therefore, for any pipe or other item employing a torus 40 . The torus 40 has a central opening 40 b and may, according to the present invention, also include one, two or more RFIDT's (not shown).
FIGS. 2F and 2G show a torus 44 according to the present invention insertable into any recess disclosed herein which has a body 45 , a central opening 44 a , and a series of voids 46 a , 46 b , and 46 c . With such a torus 44 made of metal, the voids 46 a - 46 c can be sensed by any sensing apparatus or method disclosed herein and provide a unique sensible signature for the torus 44 and for any item employing such a torus 44 . Any torus described herein may have such a series of voids and any such series of voids may, according to the present invention, contain any desired number (one or more) of voids of any desired dimensions. In one particular aspect, a series of voids provides a barcode which is readable by suitable known barcode reading devices. A torus 44 can be used with or without a cap ring. As desired, as is true of any torus according to the present invention, one, two, or more RFIDT's may be used within or on the torus body. Voids may be made by machining, by drilling, by etching, by laser etching, by hardfacing or using a photovoltaic process.
FIG. 2H shows a torus 47 according to the present invention useful in any recess of any embodiment herein which has a series of sensible ridges 48 a - 48 f which can be made by adding material to a torus body 49 [such a torus may have visually readable indicia, e.g. alpha (letter) and/or numeric characters]. Any torus, ring, or cap ring herein may have one or more such ridges and the ridges can have different cross-sections (e.g. as in FIG. 2H ) or similar cross-sections and they can be any suitable material, including, but not limited to metal, plastic, epoxy, carbides, and hardfacing. Also, according to the present invention, a cap ring with one or more RFIDT's and/or any other sensible material and/or indicia disclosed herein may be placed around and secured to a tubular's pin end or box end without using a recess.
FIG. 2M shows a cap ring 22 a , like the cap ring 22 , but with sensible indicia 22 b - 22 f made therein or thereon for sensing by an optical sensing system, an ultrasonic sensing system, an eddy current sensing system, a barcode sensing system, or a microwave sensing system. A cap ring 22 a may be releasably or permanently installed in or over a recess like any recess disclosed herein. The indicia 22 b - 22 f may be like any of the indicia or sensible structures disclosed herein.
FIGS. 2I and 2J show a specific cap ring 50 according to the present invention for use with drill pipe having a pin end. The ring 50 has a body with an outer diameter 50 a of 98 mm, a thickness 50 b of 5 mm, and a wall thickness 50 c of 5 mm. FIGS. 2K and 2L show a specific cap ring 51 according to the present invention for use with a drill pipe pin end having an end portion diameter of about four inches. The ring 51 has an outer diameter 51 a of 98 mm, a thickness 51 b of 8 to 10 mm, and a wall thickness 51 c of 3 mm.
It is within the scope of the present invention to provide a tubular having a box end and a pin end (each threaded or not) (e.g. casing, riser, pipe, drill pipe, drill collar, tubing), each end with an RFIDT in a recess therein (as any recess described herein) with or without a cap ring (as any described herein). FIGS. 3A-3C show a generally cylindrical hollow tubular member 480 according to the present invention with a flow channel 480 a therethrough from top to bottom and which has a threaded pin end 481 and a threaded box end 482 . The threaded box end 482 has a circumferential recess 483 with an RFIDT 484 therein. The RFIDT has an IC 485 and an antenna 486 which encircles the box end. Optionally, filler material 487 in the recess 483 encases and protects the IC 485 and the antenna 486 ; and an optional circular cap ring 488 closes off the recess. The RFIDT and its parts and the cap ring may be as any disclosed or referred to herein. Optionally, the tubular member 480 may have a shoulder recess 483 a with an RFIDT 484 a with an IC 485 a and an antenna 486 a . Filler material 487 a (optional) encases the RFIDT 484 a and, optionally, a cap ring 488 a closes off the recess.
The pin end 481 has a circumferential recess 491 in which is disposed an RFIDT 492 with an IC 493 and an antenna 494 around the pin end. As with the box end, filler material and/or a cap ring may be used with the recess 491 . Antenna size is related to how easy it is to energize an IC and, therefore, the larger the antenna, the easier [less power needed and/or able to energize at a greater distance] to energize: and, due to the relatively large circumference of some tubulars, energizing end antennas is facilitated.
FIG. 4A shows a system 70 according to the present invention with a rig 60 according to the present invention which has in a rig floor 61 a reading system 65 (shown schematically) for reading one or more RFIDT's in a drill pipe 66 which is to be used in drilling a wellbore. The reading system 65 incorporates one or more known reading apparatuses for reading RFIDT's, including, but not limited to suitable readers as disclosed in the prior art and readers as commercially available from MBBS Co. of Switzerland. The present invention provides improvements of the apparatuses and systems disclosed in U.S. patent application Ser. No. 09/906,957 filed Jul. 16, 2001 and published on Feb. 7, 2002 as Publication No. 2002/0014966. In an improved system 70 according to the present invention a drill pipe 66 ( FIG. 4B ) is like the drill pipes 16 in U.S. patent application Ser. No. 09/906,957, but the drill pipe 66 has a recess 67 with a torus 68 therein having at least one RFIDT 69 (shown schematically in FIG. 4B ) and a cap ring 68 a over the torus 68 . The drill pipe 66 may be connected with a tool joint 76 to other similar pieces of drill pipe in a drill string 77 (see FIG. 4A ) as in U.S. patent application Ser. No. 09/906,957 (incorporated fully herein) and the systems and apparatuses associated with the system 70 ( FIG. 4A and FIG. 4C ) operate in a manner similar to that of the systems 10 and the system of FIG. 1B of said patent application. Drill string 77 includes a plurality of drill pipes 66 coupled by a plurality of tool joints 76 and extends through a rotary table 78 , and into a wellbore through a bell nipple 73 mounted on top of a blowout preventer stack 72 . An identification tag (e.g. an RFIDT) 71 is provided on one or more drilling components, such as illustrated in FIG. 4A , associated with the system 70 , or the drill pipe 66 . An electromagnetic signal generator system 74 that includes an antenna and a signal generator is positioned proximate to an identification tag, for example just below rotary table 78 as illustrated in FIG. 4A . Electromagnetic signal generator system 74 establishes a communications link with an identification tag 71 to energize the antenna, interrogate it, and to convey information relating to the equipment or drill pipe.
The drilling system 70 includes the rig 60 with supports 83 , a swivel 91 , which supports the drill string 77 , a kelly joint 92 , a kelly drive bushing 93 , and a spider 79 with an RFIDT sensor and/or reader 79 a . A tool joint 76 is illustrated in FIG. 4A as connecting two drilling components such as drill pipes 66 . The identification tag 71 (or the RFIDT 69 read by the system 65 ) is operated to communicate a response to an incoming electromagnetic signal generated by electromagnetic signal generator system 74 (or by the system 65 ) that includes information related to the drilling component with the identification tag. The information may be used, for example, to inform an operator of system 70 of a drilling component's identity, age, weaknesses, previous usage or adaptability. According to the teachings of the present invention, this information may be communicated while drill system 70 is in operation. Some or all of the information provided in an identification tag may assist an operator in making a determination of when drilling components need to be replaced, or which drilling components may be used under certain conditions. The electromagnetic signal communicated by an identification tag or RFIDT may provide general inventory management data (such as informing an operator of the drilling components availability on the drilling site, or the drilling component's size, weight, etc.), or any other relevant drilling information associated with the system.
Additional drill string components 84 , which are illustrated in FIG. 4A in a racked position, may be coupled to drill pipe 66 and inserted into the well bore, forming a portion of the drill string. One or more of drill string components may also include identification tags or RFIDT's.
FIG. 4C shows typical information that may be included within an identification tag's or RFIDT's, antenna as the antenna cooperates with electromagnetic signal generator 74 and/or the system 65 to transmit an electromagnetic energizing signal 85 to an identification tag 71 (or 69 ). The electromagnetic signal generators use an antenna to interrogate the RFIDT's for desired information associated with a corresponding pipe or drilling component.
The electromagnetic signal 85 is communicated to an RFIDT that responds to the transmitted electromagnetic signal by returning data or information 86 in an electromagnetic signal form that is received by one of the antennas, and subsequently communicated to a reader 87 which may subsequently process or simply store electromagnetic signal 86 . The reader 87 may be handheld, i.e. mobile, or fixed according to particular needs.
The RFIDT's 69 and 71 may be passive (e.g. requiring minimal incident power, for example power density in the approximate range of 15-25 mW/cm 2 ) in order to establish a communications link between an antenna and the RFIDT. “Passive” refers to an identification tag not requiring a battery or any other power source in order to function and to deriving requisite power to transmit an electromagnetic signal from an incoming electromagnetic signal it receives via an antenna. Alternatively, an RFIDT (as may any in any embodiment herein) may include a battery or other suitable power source that would enable an RFIDT to communicate an electromagnetic signal response 86 .
Antennas are coupled to reader 87 by any suitable wiring configuration, or alternatively, the two elements may communicate using any other appropriate wireless apparatus and protocol. The reader 87 is coupled to a control system which in one aspect is a computer (or computers) 88 which may include a monitor display and/or printing capabilities for the user. Computer 88 may be optionally coupled to a handheld reader 89 to be used on the rig or remote therefrom. Computer 88 may also be connected to a manual keyboard 89 a or similar input device permitting user entry into computer 88 of items such as drill pipe identity, drill string serial numbers, physical information (such as size, drilling component lengths, weight, age, etc.) well bore inclination, depth intervals, number of drill pipes in the drill string, and suspended loads or weights, for example.
The computer 88 may be coupled to a series of interfaces 90 that may include one or more sensors capable of indicating any number of elements associated with drill rig derrick 83 , such as: a block travel characteristic 90 a , a rotation counter characteristic 90 b , a drill string weight 90 c , a heave compensator 90 d , and a blowout preventer (BOP) distance sensor 90 e . A micro-controller may include one or more of these sensors or any other additional information as described in U.S. application Ser. No. 09/906,957. The control system may be or may include a microprocessor based system and/or one or more programmable logic controllers.
A drill pipe 66 with an RFIDT 69 and an RFIDT 71 provides a redundancy feature for identification of the drill pipe 66 so that, in the event one of the RFIDT's fails, the other one which has not failed can still be used to identify the particular drill pipe. This is useful, e.g. when the RFIDT 71 , which has relatively more exposure to down hole conditions, fails. Then the RFIDT 69 can still be used to identify the particular piece of drill pipe. It is within the scope of the present invention for any item according to the present invention to have two (or more RFIDT's like the RFIDT 69 and the RFIDT 71 . Optionally, or in addition to the RFIDT 69 , an RFIDT 69 a (or RFIDT's 69 a ) may be affixed exteriorly of the pipe 66 with wrap material 69 b (as described below, e.g. as in FIGS. 25-32 ).
FIGS. 5A-5D present improvements according to the present invention of prior art systems and apparatuses in U.S. Pat. No. 6,480,811 B2 issued Nov. 12, 2002 (incorporated fully herein for all purposes). FIG. 5B shows schematically and partially a drill pipe 91 with an RFIDT 92 (like the identifier assemblies 12 , U.S. Pat. No. 6,604,063 B2 or like any RFIDT disclosed herein and with an RFIDT 99 , (as any RFIDT disclosed herein in a drill pipe's pin end). It is within the scope of the present invention to provide any oilfield equipment disclosed in U.S. Pat. No. 6,604,063 B2 with two (or more) RFIDT's (e.g., one in an end and one in a side, e.g. like those shown in FIG. 5B ).
FIGS. 5A, 5C and 5D show an oilfield equipment identifying apparatus 100 according to the present invention for use with pipe or equipment as in FIG. 5B with two (or more) RFIDT's on respective pieces 114 of oilfield equipment. The RFIDT's may be any disclosed or referred to herein and those not mounted in a recess according to the present invention may be as disclosed in U.S. Pat. No. 6,480,811 B2 indicated by the reference numerals 112 a and 112 b on pieces of equipment 114 a and 114 b with RFIDT's in recesses according to the present invention shown schematically and indicated by reference numerals 109 a , 109 b ; and/or one or more RFIDT's may be affixed exteriorly (see e.g., FIGS. 25, 26 ) to either piece 114 of oilfield equipment. Each of the identifier assemblies 112 and RFIDT's like 109 a , 109 b are capable of transmitting a unique identification code for each piece of pipe or oilfield equipment.
The oilfield equipment identifying apparatus 100 with a reader 118 is capable of reading each of the identifier assemblies and RFIDT's. The reader 118 includes a hand-held wand 120 , which communicates with a portable computer 122 via a signal path 124 . In one embodiment, each identifier assembly 112 includes a passive circuit as described in detail in U.S. Pat. No. 5,142,128 (fully incorporated herein for all purposes) and the reader 118 can be constructed and operated in a manner as set forth in said patent or may be any other reader or reader system disclosed or referred to herein.
In use, the wand 120 of the reader 118 is positioned near a particular one of the identifier assemblies 112 or RFIDT's. A unique identification code is transmitted from the identifier assembly or RFIDT to the wand 120 via a signal path 126 which can be an airwave communication system. Upon receipt of the unique identification code, the wand 120 transmits the unique identification code to the portable computer 122 via the signal path 124 . The portable computer 122 receives the unique identification code transmitted by the wand 120 and then decodes the unique identification code, identifying a particular one of the identifier assemblies 112 or RFIDT's and then transmitting (optionally in real time or in batch mode) the code to a central computer (or computers) 132 via a signal path 134 . The signal path 134 can be a cable or airwave transmission system.
FIG. 5C shows an embodiment of an oilfield equipment identifying apparatus 100 a according to the present invention which includes a plurality of the identifier assemblies 112 and/or RFIDT's 109 which are mounted on respective pieces 114 of pipe or oilfield equipment as described above. The oilfield equipment identifying apparatus includes a reader 152 , which communicates with the central computer 132 . The central computer 132 contains an oilfield equipment database (which in certain aspects, can function as the oilfield equipment database set forth in U.S. Pat. No. 5,142,128). In one aspect the oilfield equipment database in the central computer 132 may function as described in U.S. Pat. No. 5,142,128. In one aspect the oilfield equipment identifying apparatus 100 a is utilized in reading the identifier assemblies 112 (and/or RFIDT's 109 ) on various pieces 114 of pipe or oilfield equipment located on a rig floor 151 of an oil drilling rig.
The reader 152 includes a hand-held wand 156 (but a fixed reader apparatus may be used). The hand-held wand 156 is constructed in a similar manner as the hand-held wand 120 described above. The wand 156 may be manually operable and individually mobile. The hand-held wand 156 is attached to a storage box 158 via a signal path 160 , which may be a cable having a desired length. Storage box 158 is positioned on the rig floor 151 and serves as a receptacle to receive the hand-held wand 156 and the signal path 160 when the hand-held wand 156 is not in use.
An electronic conversion package 162 communicates with a connector on the storage box 158 via signal path 164 , which may be an airway or a cable communication system so that the is electronic conversion package 162 receives the signals indicative of the identification code stored in the identifier assemblies 112 and/or RFIDT's, which are read by the hand-held wand 156 . In response to receiving such signal, the electronic conversion package 162 converts the signal into a format which can be communicated an appreciable distance therefrom. The converted signal is then output by the electronic conversion package 162 to a buss 166 via a signal path 168 . The buss 166 , which is connected to a drilling rig local area network and/or a programmable logic controller (not shown) in a well-known manner, receives the converted signal output by the electronic conversion package 162 .
The central computer 132 includes an interface unit 170 . The interface 170 communicates with the central computer 132 via a signal path 172 or other serial device, or a parallel port. The interface unit 170 may also communicates with the buss 166 via a signal path 173 . The interface unit 170 receives the signal, which is indicative of the unique identification codes and/or information read by the hand-held wand 156 , from the buss 166 , and a signal from a drilling monitoring device 174 via a signal path 176 . The drilling monitoring device 174 communicates with at least a portion of a drilling device 178 ( FIG. 5D ) via a signal path 179 . The drilling device 178 can be supported by the rig floor 151 , or by the drilling rig. The drilling device 178 can be any drilling device which is utilized to turn pieces 114 of oilfield equipment, such as drill pipe, casing (in casing drilling operations) or a drill bit to drill a well bore. For example, but not by way of limitation, the drilling device 178 can be a rotary table supported by the rig floor 151 , or a top mounted drive (“top drive”) supported by the drilling rig, or a downhole mud motor suspended by the drill string and supported by the drilling rig. Optionally, the drilling device 178 has at least one RFIDT 178 a therein or t hereon and an RFIDT reader 178 b therein or thereon. The RFIDT reader 178 a is interconnected with the other systems as is the reader 152 , e.g. via the signal path 173 as indicated by the dotted line 173 a.
The drilling monitoring device 174 monitors the drilling device 178 so as to determine when the piece 114 or pieces 114 of oilfield equipment in the drill string are in a rotating condition or a non-rotating condition. The drilling monitoring device 174 outputs a signal to the interface unit 170 via the signal path 176 , the signal being indicative of whether the piece(s) 114 of oilfield equipment are in the rotating or the non-rotating condition. The central computer 132 may be loaded with a pipe and identification program in its oilfield equipment database which receives and automatically utilizes the signal received by the interface unit 170 from the signal path 176 to monitor, on an individualized basis, the rotating and non-rotating hours of each piece 114 of oilfield equipment in the drill string.
For example, when the drilling device 178 is a downhole mud motor (which selectively rotates the drill string's drill bit while the drill string's pipe remains stationary), the central computer 132 logs the non-rotating usage of each piece 114 of the drill string's pipe. In the case where the drilling device 178 is the downhole mud motor, the central computer 132 has stored therein a reference indicating that the drilling device 178 is the downhole mud motor so that the central computer 132 accurately logs the non-rotating usage of each piece 114 of oilfield equipment included in the drill string that suspends the drilling device 178 .
FIG. 5D shows a system 250 according to the present invention for rotating pieces of drill pipe 114 which have at least one identifier assembly 112 and/or one RFIDT in a pin end (or box end, or both) recess according to the present invention to connect a pin connection 252 of the piece 114 to a box connection 254 of an adjacently disposed piece 114 in a well known manner. Each piece 114 may have an RFIDT in its pin end and/or box end. The system 250 includes a reader system 250 a (shown schematically) for reading the RFIDT in the pin end recess prior to makeup of a joint. The apparatus 250 can be, for example, but not by way of limitation, an Iron Roughneck, an ST-80 Iron Roughneck, or an AR 5000 Automated Iron Roughneck from Varco International and/or apparatus as disclosed in U.S. Pat. Nos. 4,603,464; 4,348,920; and 4,765,401. The reader system 250 a may be located at any appropriate location on or in the apparatus 250 .
The apparatus 250 is supported on wheels 256 which engage tracks (not shown) positioned on the rig floor 151 for moving the apparatus 250 towards and away from the well bore. Formed on an upper end of the apparatus 250 is a pipe spinner assembly 258 (or tong or rotating device) for selectively engaging and turning the piece 114 to connect the pin connection 252 to the box connection 254 . Optionally the assembly 258 has an RFIDT reader 258 a . An optional funnel-shaped mudguard 260 can be disposed below the pipe spinner assembly 258 . The mudguard 260 defines a mudguard bore 262 , which is sized and adapted so as to receive the piece 114 of oilfield equipment therethrough. The apparatus 250 also may include a tong or a torque assembly or torque wrench 263 disposed below the pipe spinner assembly 258 . An opening 264 is formed through the mudguard 260 and communicates with a mudguard bore 262 . Optionally an oilfield equipment identifying apparatus 110 includes a fixed mount reader 266 for automating the reading of the RFIDT's and of the identifier assemblies 112 , rather than the hand-held wand 156 . In one embodiment a flange 268 is located substantially adjacent to the opening 264 so as to position the fixed mount reader 266 through the opening 264 whereby the fixed mount reader 266 is located adjacent to the piece 114 of oilfield equipment when the piece 114 of oilfield equipment is moved and is being spun by the pipe spinner assembly 258 . The reader(s) of the apparatus 250 are interconnected with an in communication with suitable control apparatus, e.g. as any disclosed herein. In certain aspects, the fixed mount reader 266 can be located on the apparatus 250 below the pipe spinner assembly 258 and above the torque assembly or torque wrench 263 , or within or on the spinner assembly 258 ; or within or on the torque wrench 263 .
The prior art discloses a variety of tubular members including, but not limited to casing, pipe, risers, and tubing, around which are emplaced a variety of encompassing items, e.g., but not limited to centralizers, stabilizers, and buoyant members. According to the present invention these items are provided with one or more RFIDT's with antenna(s) within and encircling the item and with a body or relatively massive part thereof protecting the RFIDT. FIG. 6 shows schematically a tubular member 190 with an encompassing item 192 having therein an RFIDT 194 (like any disclosed or referred to herein as may be the case for all RFIDT's mentioned herein) with an IC (integrated circuit) or microchip 196 to which is attached an antenna 198 which encircles the tubular member 190 (which is generally cylindrical and hollow with a flow channel therethrough from one end to the other or which is solid) and with which the IC 196 can be energized for reading and/or for writing thereto. In one aspect the RFIDT 194 is located midway between exterior and interior surfaces of the encompassing item 192 ; while in other aspects it is nearer to one or these surfaces than the other. The encompassing item may be made of any material mentioned or referred to herein. The RFIDT 194 is shown midway between a top and a bottom (as viewed in FIG. 6 ) of the encompassing item 192 ; but it is within the scope of this invention to locate the RFIDT at any desired level of the encompassing item 192 . Although the encompassing item 192 is shown with generally uniform dimensions, it is within the scope of the present invention for the encompassing item to have one or more portions thicker than others; and, in one particular aspect, the RFIDT (or the IC 196 or the antenna 198 ) is located in the thicker portion(s). In certain particular aspects the encompassing item is a centralizer, stabilizer, or protector. Optionally, or in addition to the RFIDT 194 , one or more RFIDT's 194 a in wrap material 194 b may be affixed exteriorly (see e.g., FIGS. 25, 26 ) of the member 190 and/or of the encompassing item 192 .
FIG. 7A shows a buoyant drill pipe 200 which is similar to such pipes as disclosed in U.S. Pat. No. 6,443,244 (incorporated fully herein for all purposes), but which, as shown in FIG. 7A , has improvements according to the present invention. The drill pipe 200 has a pin end 202 and a box end 204 at ends of a hollow tubular body 206 having a flow channel (not shown) therethrough. A buoyant element 210 encompasses the tubular body 206 . Within the buoyant element 210 is at least one RFIDT 208 which may be like and be located as the RFIDT 198 , FIG. 6 . As shown in FIG. 7B , in one aspect the buoyant member 210 has two halves which are emplaced around the tubular body 206 and then secured together. In such an embodiment either one or both ends of an antenna 201 are releasably connectable to an IC 203 of an RFIDT 208 or two parts of the antenna 201 itself are releasably connectable. As shown in FIG. 7B , antenna parts 201 a and 201 b are releasably connected together, e.g. with connector apparatus 201 c , and an end of the antenna part 201 b is releasably connected to the IC 203 . Alternatively an optional location provides an RFIDT that is entirely within one half of the buoyant member 210 , e.g. like the optional RFIDT 208 a shown in FIG. 7A . The pin end 202 may have any RFIDT therein and/or cap ring according to the present invention as disclosed herein. The two halves of the buoyant member may be held together by adhesive, any known suitable locking mechanism, or any known suitable latch mechanism (as may be any two part ring or item herein according to the present invention).
It is within the scope of the present invention to provide a stabilizer as is used in oil and gas wellbore operations with one or more RFIDT's. FIGS. 8A and 8B show a stabilizer 220 according to the present invention which is like the stabilizers disclosed in U.S. Pat. No. 4,384,626 (incorporated fully herein for all purposes) but which has improvements according to the present invention. An RFIDT 222 (like any disclosed or referred to herein) is embedded within a stabilizer body 224 with an IC 223 in a relatively thicker portion 221 of the body 224 and an antenna 225 that is within and encircles part of the body 224 . Parts 225 a and 225 b of the antenna 225 are connected together with a connector 226 . The stabilizer 220 may, optionally, have a recess at either end with an RFIDT therein as described herein according to the present invention. Optionally, the stabilizer 220 may have one or more RFIDT's located as are the RFIDT's in FIGS. 6 and 7A .
Various stabilizers have a tubular body that is interposed between other tubular members, a body which is not clamped on around an existing tubular members. According to the present invention such stabilizers may have one or more RFIDT's as disclosed herein; and, in certain aspects, have an RFIDT located as are the RFIDT's in FIG. 6, 7A or 8A and/or an RFIDT in an end recess (e.g. pin end and/or box end) as described herein according to the present invention. FIGS. 8C and 8D show a stabilizer 230 according to the present invention which has a tubular body 231 and a plurality of rollers 232 rotatably mounted to the body 231 (as in the stabilizer of U.S. Pat. No. 4,071,285, incorporated fully herein, and of which the stabilizer 230 is an improvement according to the present invention). An RFIDT 233 with an IC 234 and an antenna 235 is disposed within one or the rollers 232 . The stabilizer 230 has a pin end 236 and a box end 237 which permit it to be threadedly connected to tubulars at either of its ends. A recess may, according to the present invention, be provided in the pin end 236 and/or the box end 237 and an RFIDT and/or cap ring used therewith as described herein according to the present invention. The antenna 235 is within and encircles part of the roller 232 .
It is within the scope of the present invention to provide a centralizer with one or more RFIDT's as disclosed herein. A centralizer 240 , FIG. 8E , is like the centralizers disclosed in U.S. Pat. No. 5,095,981 (incorporated fully herein), but with improvements according to the present invention. FIGS. 8E and 8F show the centralizer 240 on a tubular TR with a hollow body 241 with a plurality of spaced-apart ribs 242 projecting outwardly from the body 241 . A plurality of screws 244 releasably secure the body 241 around the tubular TR. An RFIDT 245 with an IC 246 and an antenna 247 is located within the body 241 . Optionally a plug 241 a (or filler material) seals off a recess 241 b in which the IC 246 is located. Optionally, or in addition to the RFIDT 245 one or more RFIDT's 245 a are affixed exteriorly of the centralizer 240 under multiple layers of wrap material 245 b (see, e.g., FIGS. 25, 26 ).
FIGS. 8G and 8H show a centralizer 270 according to the present invention which is like centralizers (or stabilizers) disclosed in U.S. Pat. No. 4,984,633 (incorporated fully herein for all purposes), but which has improvements according to the present invention. The centralizer 270 has a hollow tubular body 271 with a plurality of spaced-apart ribs 272 projecting outwardly therefrom. An RFIDT 273 with an IC 274 and an antenna 275 (dotted circular line) is disposed within the body 271 with the IC 274 within one of the ribs 272 and the antenna 275 within and encircling part of the body 271 . Optionally, or in addition to the RFIDT 273 , one or more RFIDT's 273 a is affixed exteriorly to the centralizer 270 under layers of wrap material 273 b (see, e.g. FIGS. 25, 26 ).
Often thread protectors are used at the threaded ends of tubular members to prevent damage to the threads. It is within the scope of the present invention to provide a thread protector, either a threaded thread protector or a non-threaded thread protector, with one or more RFIDT's as disclosed herein. FIGS. 9A, 10A, and 11 show examples of such thread protectors.
FIGS. 9A and 9B and 10A and 10B show thread protectors like those disclosed in U.S. Pat. No. 6,367,508 (incorporated fully herein), but with improvements according to the present invention.
A thread protector 280 , FIG. 9A , according to the present invention protecting threads of a pin end of a tubular TB has an RFIDT 283 within a body 282 . The RFIDT 283 has an IC 284 and an antenna 285 . A thread protector 281 , FIG. 9B , according to the present invention protecting threads of a box end of a tubular TL has a body 286 and an RFIDT 287 with an IC 288 and an antenna 298 within the body 286 . Both the bodies 282 and 286 are generally cylindrical and both antennas 285 and 298 encircle a part of their respective bodies. Optionally the thread protector 281 has an RFIDT 287 a within a recess 286 a of the body 286 . The RFIDT 287 a has an IC 288 a and an antenna 289 a . Optionally, any thread protector herein may be provided with a recess according to the present invention as described herein with an RFIDT and/or torus and/or cap ring according to the present invention (as may any item according to the present invention as in FIGS. 6-8G ). Optionally, or in addition to the RFIDT 283 , one or more RFIDT's 283 a is affixed exteriorly (see, e.g., FIGS. 25, 26 ) to the thread protector 280 under layers of wrap material 283 b.
FIGS. 10A and 10B show a thread protector 300 according to the present invention which is like thread protectors disclosed in U.S. Pat. No. 6,367,508 B1 (incorporated fully herein), but with improvements according to the present invention. The thread protector 300 for protecting a box end of a tubular TU has a body 302 with upper opposed spaced-apart sidewalls 303 a , 303 b . An RFIDT 304 with an IC 305 and an antenna 306 is disposed between portions of the two sidewalls 303 a , 303 b . Optionally, an amount of filler material 307 (or a cap ring as described above) is placed over the RFIDT 304 . Optionally, or as an alternative, an RFIDT 304 a is provided within the body 302 with an IC 305 a and an antenna 306 a . Optionally, or as an alternative, an RFIDT 304 b is provided within the body 302 with an IC 305 b and an antenna 306 b.
A variety or prior art thread protectors have a strap or tightening apparatus which permits them to be selectively secured over threads of a tubular. FIG. 11 shows a thread protector 310 according to the present invention which is like the thread protectors disclosed in U.S. Pat. No. 5,148,835 (incorporated fully herein), but with improvements according to the present invention. The thread protector 310 has a body 312 with two ends 312 a and 312 b . A strap apparatus 313 with a selectively lockable closure mechanism 314 permits the thread protector 310 to be installed on threads of a tubular member. An RFIDT 315 with an IC 316 and an antenna 317 is disposed within the body 312 . The antenna 317 may be connected or secured to, or part of, the strap apparatus 313 and activation of the lockable closure mechanism 314 may complete a circuit through the antenna. In one aspect the antenna has ends connected to metallic parts 318 , 319 and the antenna is operational when these parts are in contact. The bodies of any thread protector according to the present invention may be made of any material referred to herein, including, but not limited to, any metal or plastic referred to herein or in the patents incorporated by reference herein.
FIG. 12A shows a system 400 according to the present invention which has a rig 410 that includes a vertical derrick or mast 412 having a crown block 414 at its upper end and a horizontal rig floor 416 at its lower end. Drill line 418 is fixed to deadline anchor 420 , which is commonly provided with hook load sensor 421 , and extends upwardly to crown block 414 having a plurality of sheaves (not shown). From block 414 , drill line 418 extends downwardly to traveling block 422 that similarly includes a plurality of sheaves (not shown). Drill line 418 extends back and forth between the sheaves of crown block 414 and the sheaves of traveling block 422 , then extends downwardly from crown block 414 to drawworks 424 having rotating drum 426 upon which drill line 418 is wrapped in layers. The rotation of drum 426 causes drill line 418 to be taken in or out, which raises or lowers traveling block 422 as required. Drawworks 424 may be provided with a sensor 427 which monitors the rotation of drum 426 . Alternatively, sensor 427 may be located in crown block 414 to monitor the rotation of one or more of the sheaves therein. Hook 428 and any elevator 430 is attached to traveling block 422 . Hook 428 is used to attach kelly 432 to traveling block 422 during drilling operations, and elevators 430 are used to attach drill string 434 to traveling block 422 during tripping operations. Shown schematically the elevator 430 has an RFIDT reader 431 (which may be any reader disclosed or referred to herein and which is interconnected with and in communication with suitable control apparatus, e.g. as any disclosed herein, as is the case for reader 439 and a reader 444 . Drill string 434 is made up of a plurality of individual drill pipe pieces, a grouping of which are typically stored within mast 412 as joints 435 (singles, doubles, or triples) in a pipe rack. Drill string 434 extends down into wellbore 436 and terminates at its lower end with bottom hole assembly (BHA) 437 that typically includes a drill bit, several heavy drilling collars, and instrumentation devices commonly referred to as measurement-while-drilling (MWD) or logging-while-drilling (LWD) tools. A mouse hole 438 , which may have a spring at the bottom thereof, extends through and below rig floor 416 and serves the purpose of storing next pipe 440 to be attached to the drill string 434 . With drill pipe according to the present invention having an RFIDT 448 in a pin end 442 , an RFIDT reader apparatus 439 at the bottom of the mouse hole 438 can energize an antenna of the RFIDT 448 and identify the drill pipe 440 . Optionally, if the drill pipe 440 has an RFIDT in a box end 443 , an RFIDT reader apparatus can energize an antenna in the RFIDT 446 and identify the drill pipe 440 . Optionally, the drill bit 437 has at least one RFIDT 437 a (any disclosed herein) (shown schematically). Optionally, or in addition to the RFIDT 448 , the drill pipe 440 has one or more RFIDT's 448 a affixed exteriorly to the drill pipe 440 (see, e.g., FIGS. 25, 26 ) under wrap layers 448 b.
During a drilling operation, power rotating means (not shown) rotates a rotary table (not shown) having rotary bushing 442 releasably attached thereto located on rig floor 416 . Kelly 432 , which passes through rotary bushing 442 and is free to move vertically therein, is rotated by the rotary table and rotates drill string 434 and BHA 437 attached thereto. During the drilling operation, after kelly 432 has reached its lowest point commonly referred to as the “kelly down” position, the new drill pipe 440 in the mouse hole 438 is added to the drill string 434 by reeling in drill line 418 onto rotating drum 426 until traveling block 422 raises kelly 432 and the top portion of drill string 434 above rig floor 416 . Slips 445 , which may be manual or hydraulic, are placed around the top portion of drill string 434 and into the rotary table such that a slight lowering of traveling block 422 causes slips 444 to be firmly wedged between drill string 434 and the rotary table. At this time, drill string 434 is “in-slips” since its weight is supported thereby as opposed to when the weight is supported by traveling block 422 , or “out-of-slips”. Once drill string 434 is in-slips, kelly 432 is disconnected from string 434 and moved over to and secured to new pipe 440 in mouse hole 438 . New pipe 440 is then hoisted out of mouse hole 438 by raising traveling block 422 , and attached to drill string 434 . Traveling block 422 is then slightly raised which allows slips 445 to be removed from the rotary table. Traveling block 422 is then lowered and drilling resumed. “Tripping-out” is the process where some or all of drill string 434 is removed from wellbore 436 . In a trip-out, kelly 432 is disconnected from drill string 434 , set aside, and detached from hook 428 . Elevators 430 are then lowered and used to grasp the uppermost pipe of drill string 434 extending above rig floor 416 . Drawworks 424 reel in drill line 418 which hoists drill string 434 until the section of drill string 434 (usually a “triple”) to be removed is suspended above rig floor 416 . String 434 is then placed in-slips, and the section removed and stored in the pipe rack. “Tripping-in” is the process where some or all of drill string 434 is replaced in wellbore 436 and is basically the opposite of tripping out. In some drilling rigs, rotating the drill string is accomplished by a device commonly referred to as a “top drive” (not shown). This device is fixed to hook 428 and replaces kelly 432 , rotary bushing 442 , and the rotary table. Pipe added to drill string 434 is connected to the bottom of the top drive. As with rotary table drives, additional pipe may either come from mouse hole 438 in singles, or from the pipe racks as singles, doubles, or triples. Optionally, drilling is accomplished with a downhole motor system 434 a which has at least one RFIDT 434 b (shown schematically in FIG. 12A )
As shown in FIG. 12B , the reader apparatus 439 is in communication with a control apparatus 449 (e.g. any computerized or PLC system referred to or disclosed herein) which selectively controls the reader apparatus 439 , receives signals from it and, in certain aspects, processes those signals and transmits them to other computing and/or control apparatus. Similarly when the optional reader apparatus 444 is used, it also is in communication with the control apparatus 449 and is controlled thereby. With a reader at the pin end and a reader at the box end, the length of the piece of drill pipe be determined and/or its passage beyond a certain point. In one aspect the reader apparatus 439 is deleted and the reader apparatus 444 reads the RFIDT (or PFIDT's) in and/or on the drill pipe 440 as the drill pipe 440 passes by the reader apparatus 444 as the drill pipe 440 is either lowered into the mouse hole 438 or raised out of it. The reader apparatus 444 may be located on or underneath the rig floor 416 . It is within the scope of the present invention to use a reader apparatus 439 and/or a reader apparatus 444 in association with any system's mouse hole or rat hole (e.g., but not limited to, systems as disclosed in U.S. Pat. Nos. 5,107,705; 4,610,315; and in the prior art cited therein), and with so-called “mouse hole sleeves” and mouse hole scabbards” as disclosed in, e.g. U.S. Pat. Nos. 5,351,767; 4,834,604; and in the prior art references cited in these two patents. With respect to the drilling operation depicted in FIG. 12A (and, any drilling operation referred to herein according to the present invention) the drilling may be “casing drilling” and the drill pipe can be casing.
FIGS. 13A and 13B show a system 450 according to the present invention which has a mouse hole 451 associated with a rig 452 (shown partially). The mouse hole 451 includes a mouse hole scabbard 454 (shown schematically, e.g. like the one in U.S. Pat. No. 4,834,604, but with improvements according to the present invention). The mouse hole scabbard 454 includes an RFIDT reader apparatus 456 (like any such apparatus described or referred to herein) with connection apparatus 458 via which a line or cable 459 connects the reader apparatus 456 to control apparatus 455 (shown schematically, like any described or referred to herein). It is within the scope of the present invention to provide, optionally, reader apparatuses (E.G. other than adjacent the pipe or adjacent a mouse hole, or tubular preparation hole) 453 and/or 459 on the rig 452 . Optionally, one or more antenna energizers are provided on a rig and reader apparatuses are located elsewhere. According to the present invention a scabbard can be made of nonmagnetic metal, plastic, polytetrafluoroethylene, fiberglass or composite to facilitate energizing of an RFIDT's antenna of an RFIDT located within the scabbard. Optionally a scabbard may be tapered to prevent a pipe end from contacting or damaging the reader apparatus 456 and/or, as shown in FIG. 13B , stops 454 a may be provided to achieve this.
Various prior art systems employ apparatuses known as “powered mouse holes” or “rotating mouse hole tools”. It is within the scope of the present invention to improve such systems with an RFIDT reader apparatus for identifying a tubular within the powered mouse hole. FIGS. 14A-14C show a system 460 according to the present invention which includes a rig system 461 and a powered mouse hole 462 . The powered mouse hole 462 is like the powered mouse hole disclosed in U.S. Pat. No. 5,351,767 (incorporated fully herein for all purposes) with the addition of an RFIDT reader apparatus. The powered mouse hole 462 has a receptacle 463 for receiving an end of a tubular member. An RFIDT reader apparatus 464 is located at the bottom of the receptacle 463 (which may be like any RFIDT reader apparatus disclosed or referred to herein). A line or cable 465 connects the RFIDT reader apparatus 464 to control apparatus (not shown; like any disclosed or referred to herein). Optionally as shown in FIG. 14B , an RFIDT reader apparatus 466 in communication with control apparatus 467 is located adjacent the top of the receptacle 463 .
FIG. 14D shows a rotating mouse hole tool 470 which is like the PHANTOM MOUSE™ tool commercially-available from Varco International (and which is co-owned with the present invention), but the tool 470 has an upper ring 471 on a circular receptacle 473 (like the receptacle 463 , FIG. 14C ). The upper ring 471 has an energizing antenna 472 for energizing an RFIDT on a tubular or in an end of a tubular placed into the receptacle 473 . The antenna 472 encircles the top of the receptacle 473 . The antenna 472 is connected to reader apparatus 474 (like any disclosed or referred to herein) which may be mounted on the tool 470 or adjacent thereto.
The prior art discloses a wide variety of top drive units (see, e.g., U.S. Pat. Nos. 4,421,179; 4,529,045; 6,257,349; 6,024,181; 5,921,329; 5,794,723; 5,755,296; 5,501,286; 5,388,651; 5,368,112; and 5,107,940 and the references cited therein). The present invention discloses improved top drives which have one, two, or more RFIDT readers and/or antenna energizers. It is within the scope of the present invention to locate an RFIDT reader and/or antenna energizer at any convenient place on a top drive from which an RFIDT in a tubular can be energized and/or read and/or written to. Such locations are, in certain aspects, at a point past which a tubular or a part thereof with an RFIDT moves. FIGS. 15A and 15B show a top drive system 500 according to the present invention which is like the top drives of U.S. Pat. No. 6,679,333 (incorporated fully herein), but with an RFIDT reader 501 located within a top drive assembly portion 502 . The reader 501 is located for reading an RFIDT 503 on or in a tubular 504 which is being held within the top drive assembly portion 502 . Alternatively, or in addition to the reader 501 , an RFIDT reader 507 is located in a gripper section 505 which can energize and read the RFIDT 503 as the gripper section moves into the tubular 504 . In particular aspects, the tubular is a piece of drill pipe or a piece of casing. Appropriate cables or lines 508 , 509 , respectively connect the readers 501 , 507 to control apparatus (not shown, as any described or referred to herein).
It is within the scope of the present invention to provide a cementing plug (or pipeline pig) with one or more RFIDT's with an antenna that encircles a generally circular part or portion of the plug or pig and with an IC embedded in a body part of the plug or pig and/or with an IC and/or antenna in a recess (as any recess described or referred to herein) and/or with one or more RFIDT's affixed exteriorly of the plug or pig. FIG. 16A shows a cementing plug 510 according to the present invention with a generally cylindrical body 512 and exterior wipers 513 (there may be any desired number of wipers). An RFIDT 514 is encased in the body 512 . An antenna 515 encircles part of the body 512 . The body 512 (as may be any plug according to the present invention) may be made of any known material used for plugs, as may be the wipers 513 . An IC 516 of the RFIDT 514 is like any IC disclosed or referred to herein. Optionally a cap ring (not shown) may be used over the recess 515 as may be filler material within the recess. Optionally, or in addition to the RFIDT 514 , one or more RFIDT's 514 a is affixed exteriorly to the plug 510 under wrap layers 514 b (see, e.g. FIGS. 25, 26 ). One or more such RFIDT's may be affixed to the plug 520 .
FIG. 16B shows a cementing plug 520 according to the present invention which has a generally cylindrical body 522 with a bore 523 therethrough from top to bottom. A plurality of wipers 524 are on the exterior of the body 522 . An RFIDT 525 has an IC 526 encased in the body 522 and an antenna 527 that encircles part of the body 522 . Both antennas 515 and 527 are circular as viewed from above and extend around and within the entire circumference of their respective bodies. It is within the scope of the present invention to have the RFIDT 514 and/or the RFIDT 525 within recesses in their respective bodies (as any recess disclosed herein or referred to herein) with or without a cap ring or filler.
FIGS. 17A-17D show a portable ring 530 which has a flexible body 532 made, e.g. from rubber, plastic, fiberglass, and/or composite which has two ends 531 a , 531 b . The end 531 a has a recess 536 sized and configured for receiving and holding with a friction fit a correspondingly sized and configured pin 533 projecting out from the end 531 b . The two ends 531 a , 531 b may be held together with any suitable locking mechanism, latch apparatus, and/or adhesive. As shown, each end 531 a , 531 b has a piece of releasably cooperating hook-and-loop fastener material 534 a , 534 b , respectively thereon (e.g. VELCRO™ material) and a corresponding piece of such material 535 is releasably connected to the pieces 534 a , 534 b ( FIG. 17C ) to hold the two ends 531 a , 531 b together. The body 532 encases an RFIDT 537 which has an IC 538 and an antenna 539 . Ends of the antenna 539 meet at the projection 533 —recess 536 interface and/or the projection 533 is made of antenna material and the recess 536 is lined with such material which is connected to an antenna end. Optionally, as shown in FIG. 17D the ring 530 may include one or more (one shown) protective layers 532 a , e.g. made of a durable material, e.g., but not limited to metal, KEVLAR™ material or ARAMID™ material. A hole 532 b formed when the two ends 531 a , 531 b are connected together can be any desired size to accommodate any item or tubular to be encompassed by the ring 530 . The ring 530 may have one, two or more RFIDT's therein one or both of which are read-only; or one or both of which are read-write. Such a ring may be releasably emplaceable around a member, e.g., but not limited to, a solid or hollow generally cylindrical member. Any ring or torus herein according to the present invention may have an RFIDT with an antenna that has any desired number of loops (e.g., but not limited to, five, ten, fifteen, twenty, thirty or fifty loops), as may be the case with any antenna of any RFIDT in any embodiment disclosed herein.
FIG. 17E shows a portable ring 530 a , like the ring 530 but without two separable ends. The ring 530 a has a body 530 b made of either rigid or flexible material and with a center opening 530 f so it is releasably emplaceable around another member. An RFIDT 530 c within the body 530 b has an IC 530 e and an antenna 530 d.
It is within the scope of the present invention to provide a whipstock with one or more RFIDT's with an RFIDT circular antenna that encircles a generally circular part of a generally cylindrical part of a whipstock. FIGS. 18A and 18B show a whipstock 540 like a whipstock disclosed in U.S. Pat. No. 6,105,675 (incorporated fully herein for all purposes), but with an RFIDT 541 in a lower part 542 of the whipstock 540 . The RFIDT 541 has an antenna 543 and an IC 544 (each like any as disclosed or referred to herein). Optionally, or in addition to the RFIDT 541 , one or more RFIDT's 541 a is affixed exteriorly to the whipstock 540 under wrap layers 541 b (see, e.g., FIGS. 25, 26 ).
An RFIDT 551 (as any disclosed herein) may, according to the present invention, be provided in a generally cylindrical part of a mill or milling tool used in downhole milling operations. Also with respect to certain mills that have a tubular portion, one or both ends of such a mill may have one or more RFIDT's therein according to the present invention. FIG. 19 shows a mill 550 which is like the mill disclosed in U.S. Pat. No. 5,620,051 (incorporated fully herein), but with an RFIDT 551 in a threaded pin end 552 of a body 553 of the mill 550 . The RFIDT 551 may be emplaced and/or mounted in the pin end 552 as is any similar RFIDT disclosed herein. Optionally an RFIDT may be emplaced within a milling section 554 . Optionally, or in addition to the RFIDT 551 , one or more RFIDT's 551 a may be affixed exteriorly of the mill 550 under wrap layers 551 b (see, e.g., FIGS. 25, 26 ).
The prior art discloses a variety of pipe handlers and pipe manipulators, some with gripping mechanisms for gripping pipe. It is within the scope of the present invention to provide a pipe handler with an RFIDT reader for reading an RFIDT in a tubular member which is located in one of the embodiments of the present invention as described herein. Often an end of a tubular is near, adjacent, or passing by a part of a pipe handler. An RFIDT on or in a tubular according to the present invention can be sensed by an RFIDT reader apparatus and a signal can be transmitted therefrom to control apparatus regarding the tubular's identity or other information stored in the RFIDT. FIGS. 20A and 20B show pipe manipulators 560 and 570 [which are like pipe manipulators disclosed in U.S. Pat. No. 4,077,525 (incorporated fully herein), but with improvements according to the present invention] which have movable arms 561 , 562 , (pipe manipulator 560 ) and movable arm 571 (pipe manipulator 570 ). Each manipulator has a pipe gripper 563 , 573 . Each manipulator has an RFIDT reader apparatus—apparatus 565 on manipulator 560 and apparatus 575 on manipulator 570 . Optionally, such a reader apparatus is located on a gripper mechanism.
FIG. 21 shows a tubular inspection system 600 [which may be any known tubular inspection system, including those which move with respect to a tubular and those with respect to which a tubular moves, including, but not limited to those disclosed in U.S. Pat. Nos. 6,622,561; 6,578,422; 5,534,775; 5,043,663; 5,030,911; 4,792,756; 4,710,712; 4,636,727; 4,629,985; 4,718,277; 5,914,596; 5,585,565; 5,600,069; 5,303,592; 5,291,272; and Int'l Patent Application WO 98/16842 published Apr. 23, 1998 and in the references cited therein] which is used to inspect a tubular 610 (e.g., but not limited to pipe, casing, tubing, collar) which has at least one RFIDT 602 with an IC 604 and an antenna 606 and/or at least one RFIDT 602 a affixed exteriorly thereof according to the present invention. The tubular 610 may be any tubular disclosed herein and it may have any RFIDT, RFIDT's, recess, recesses, cap ring, and/or sensible material and/or indicia disclosed herein.
FIG. 22 shows schematically a method 620 for making a tubular member according to the present invention. A tubular body is made—“MAKE TUBULAR BODY”—using any suitable known process for making a tubular body, including, but not limited to, known methods for making pipe, drill pipe, casing, risers, and tubing. An end recess is formed—“FORM END RECESS”—in one or both ends of the tubular member. An identification device is installed in the recess—“INSTALL ID DEVICE” (which may be any identification apparatus, device, torus ring or cap ring according to the present invention). Optionally, a protector is installed in the recess—“INSTALL PROTECTOR” (which may be any protector according to the present invention).
FIG. 23 shows schematically a system 650 according to the present invention which is like the systems described in U.S. Pat. No. 4,698,631 but which is for identifying an item 652 according to the present invention which has at least one end recess (as any end recess disclosed herein) and/or within a ring or torus according to the present invention with at least one SAW tag identification apparatus 654 in the recess(es) and/or ring(s) or torus(es) and/or with an exteriorly affixed RFIDT according to the present invention.
The system 650 (as systems in U.S. Pat. No. 4,698,631) has an energizing antenna apparatus 656 connected to a reader 658 which provides radio frequency pulses or bursts which are beamed through the antenna apparatus 656 to the SAW tag identification apparatus 654 . The reader 658 senses responsive signals from the apparatus 654 . In one aspect the responsive signals are phase modulated in accord with code encoded in the apparatus 654 . The reader 658 sends received signals to a computer interface unit 660 which processes the signals and sends them to a computer system 662 .
It is within the scope of the present invention to provide a blowout preventer according to the present invention with one or more wave-energizable identification apparatuses, e.g. in a flange, side outlet, and/or door or bonnet or a blowout preventer. FIG. 24 shows a blowout preventer 670 according to the present invention which has a main body 672 , a flow bore 674 therethrough from top to bottom, a bottom flange 676 , a top flange 678 , a side outlet 682 , and four ram-enclosing bonnets 680 . An RFIDT 690 (like any disclosed herein) has an antenna 691 encircling and within the top flange 678 with an IC 692 connected thereto. An RFIDT 692 (like any disclosed herein) has an antenna 694 encircling and within the bottom flange 676 with an IC 695 . An RFIDT 696 (like any disclosed herein) has an antenna 697 encircling and within a bonnet 680 with an IC 698 . An RFIDT 684 (like any disclosed herein) has an antenna 685 encircling and within a flange 689 of the side outlet 682 , with an IC 686 . Optionally, or in addition to the other RFIDT's at least one RFIDT 690 a is affixed exteriorly to the blowout preventer 670 under wrap layers 690 b (see, e.g., FIG. 25, 26 ) and/or at least one RFIDT 690 c is affixed exteriorly to the blowout preventer 270 under wrap layers 690 d (see, e.g., FIG. 25, 26 ).
FIGS. 25 and 26 show a tool joint 700 according to the present invention with RFIDT apparatus 720 according to the present invention applied exteriorly thereto. The tool joint 700 has a pin end 702 with a threaded pin 704 , a joint body portion 706 , an upset area 707 and a tube body portion 708 . The joint body portion 706 has a larger OD than the tube body portion 708 . The “WELDLINE’ is an area in which the tool joint is welded (e.g. inertia welded) by the manufacturer to the upset area.
Although RFIDT's encased in a non-conductor or otherwise enclosed or protected can be emplaced directly on a tubular (or other item or apparatus according to the present invention, as shown in FIGS. 25 and 26 the RFIDT's to be applied to the tool joint 700 are first enclosed within non-conducting material, e.g. any suitable heat-resistant material, e.g., but not limited to, RYTON™ fabric membrane wrapping material, prior to emplacing them on the tool joint 700 . In one particular aspect, one, two, three, or four wraps, folds, or layers of commercially available RYT-WRAP™ material commercially from Tuboscope, Inc. a related company of the owner of the present invention is used which, in one particular aspect, includes three layers of RYT-WRAP™ fabric membrane material adhered together and encased in epoxy. As shown, three RFIDT's 720 are wrapped three times in the RYT-WRAP™ material 722 so that no part of any of them will contact the metal of the tool joint 700 . In one aspect such a wrapping of RYT-WRAP™ material includes RYTON™ fabric membrane material with cured epoxy wrapped around a tubular body (initially the material is saturated in place with liquid epoxy that is allowed to cure).
Prior to emplacing the wrapped RFIDT's 720 on the tool joint 700 , the area to which they are to be affixed is, preferably, cleaned using suitable cleaning materials, by buffing, and/or by sandblasting as shown in FIG. 27 . Any desired number of RFIDT's 720 may be used. As shown in FIG. 29A , in this embodiment three RFIDT's 720 are equally spaced apart around the exterior of the tool joint 700 .
According to the present invention, RFIDT's may be applied exteriorly to any item, apparatus, or tubular at any exterior location thereon with any or all of the layers and/or wraps disclosed herein. In the particular tool joint 700 as disclosed in FIG. 25 , the RFIDT's 720 are applied about two to three inches from a thirty-five degree taper 709 of the joint body portion 706 to reduce the likelihood of the RFIDT's contacting other items, handling tools, grippers, or structures that may contact the portion 706 .
Optionally, as shown in FIG. 26 , either in the initial layers or wraps which enclose the RFIDT's 720 or in any other layer or wrap, an identification tag 724 is included with the RFIDT's, either a single such tag or one tag for each RFIDT. In one aspect the tag(s) 724 are plastic or fiberglass. In another aspect the tag(s) 724 are metal, e.g. steel, stainless steel, aluminum, aluminum alloy, zinc, zinc alloy, bronze, or brass. If metal is used, the tag(s) 724 are not in contact with an RFIDT.
As shown in FIG. 28 , an adhesive may be applied to the tool joint 700 to assist in securing a layer 723 , “FOLDED MEMBRANE,” (e.g., a double layer of RYT-WRAP™ wrap material.
As shown in FIG. 29 , the three RFIDT's 720 are emplaced on the layer 723 and, optionally, the identification tag or tags 724 .
Optionally, as shown in FIG. 30 , part 723 a of the layer 723 is folded over to cover the RFIDT's 720 and the tag(s) 724 . If this folding is done, no adhesive is applied to the tool joint under the portion of the layer 723 which is to be folded over. Optionally, prior to folding adhesive is applied on top of the portion of the layer 723 to be folded over. Optionally, prior to folding the part 723 a over on the RFIDT's 720 and the tag(s) 724 an adhesive (e.g. two part epoxy) is applied over the RFIDT's 720 and over the tag(s) 724 .
After allowing the structure of layer 723 a as shown in FIG. 30 to dry (e.g., for forty minutes to one hour), as shown in FIG. 30A the folded layer 723 with the RFIDT's 720 and tag(s) 724 is, optionally, wrapped in a layer 726 of heat shrink material and/or impact resistant material (heat resistant material may also be impact resistant). In one particular optional aspect, commercially available RAYCHEM™ heat shrink material or commercially available RCANUSA™ heat shrink material is used, centered over the folded layer 723 , with, preferably, a small end-to-end overlap to enhance secure bonding as the material is heated.
As shown in FIG. 30B , optionally, the layer 726 is wrapped with layers 728 of material [e.g. RYT-WRAP™ material] (e.g. with two to five layers). In one particular aspect the layer(s) 728 completely cover the layer 726 and extend for one-half inch on both extremities of the layer 726 . Preferably, the final wrap layer of the layers 728 does not exceed the OD of the joint body portion 706 so that movement of and handling of the tool joint 700 is not impeded.
Curing can be done in ambient temperature and/or with fan-assisted dryers.
Any known wave-energizable apparatus may be substituted for any RFIDT herein.
The present invention, therefore, in at least certain aspects, provides a member having a body, the body having at least a portion thereof with a generally cylindrical portion, the generally cylindrical portion having a circumference, radio frequency identification apparatus with integrated circuit apparatus and antenna apparatus within the generally cylindrical portion of the body, and the antenna apparatus encircling the circumference of the cylindrical portion of the body. Such a member may include one or some (in any possible combination) of the following: the body having a first end spaced-apart from a second end, and the radio frequency identification apparatus positioned within the first end of the body; the first end of the body having a recess in the first end, and the radio frequency identification apparatus is within the recess; a protector in the recess covering the radio frequency identification apparatus; the body comprising a pipe; wherein the first end is a pin end of the pipe; wherein an end of the pipe has an exterior shoulder and the radio frequency identification apparatus is within the shoulder; wherein the second end is a box end of the pipe; wherein the first end is threaded externally and the second end is threaded internally; wherein the member is a piece of drill pipe with an externally threaded pin end spaced-apart from an internally threaded box end, and the body is generally cylindrical and hollow with a flow channel therethrough from the pin end to the box end, the pin end having a pin end portion with a pin end recess therearound, and the radio frequency identification apparatus within the pin end recess and the antenna apparatus encircling the pin end portion; wherein a protector in the pin end recess covers the radio frequency identification apparatus therein; wherein the protector is a cap ring within the pin end recess which covers the radio frequency identification apparatus; wherein the protector is an amount of protective material in the recess which covers the radio frequency identification apparatus; the member having a box end having a box end portion having a box end recess therein, a box end radio frequency identification apparatus within the box end recess, the box end radio frequency identification apparatus having antenna apparatus and integrated circuit apparatus, the antenna encircling the box end portion; wherein a protector in the box end covers the radio frequency identification apparatus therein; wherein the recess has a cross-section shape from the group consisting of square, rectangular, semi-triangular, rhomboidal, triangular, trapezoidal, circular, and semi-circular; wherein the generally cylindrical portion is part of an item from the group consisting of pipe, drill pipe, casing, drill bit, tubing, stabilizer, centralizer, cementing plug, buoyant tubular, thread protector, downhole motor, whipstock, blowout preventer, mill, and torus; a piece of pipe with a pin end, the pin end having a recess therein, and sensible indicia in the recess; wherein the sensible indicia is from the group consisting of raised portions, indented portions, visually sensible indicia, spaced-apart indicia, numeral indicia, letter indicia, and colored indicia; the member including the body having a side wall with an exterior surface and a wall recess in the side wall, the wall recess extending inwardly from the exterior surface, and secondary radio frequency identification apparatus within the wall recess; and/or wherein the radio frequency identification apparatus is a plurality of radio frequency identification tag devices.
The present invention, therefore, in at least certain aspects, provides a tubular member with a body with a first end spaced-apart from a second end, the first end having a pin end having a pin end recess in the first end and identification apparatus in the pin end recess, and a protector in the pin end recess protecting the identification apparatus therein.
The present invention, therefore, in at least certain aspects, provides a method for sensing a radio frequency identification apparatus in a member, the member having a body, the body having at least a portion thereof with a generally cylindrical portion, the generally cylindrical portion having a circumference, wave-energizable identification apparatus with antenna apparatus within the generally cylindrical portion of the body, and the antenna apparatus encircling the circumference of the cylindrical portion of the body, the method including energizing the wave-energizable identification apparatus by directing energizing energy to the antenna apparatus, the wave-energizable identification apparatus upon being energized producing a signal, positioning the member adjacent sensing apparatus, and sensing with the sensing apparatus the signal produced by the wave-energizable identification apparatus. Such a method may include one or some (in any possible combination) of the following: wherein the sensing apparatus is on an item from the group consisting of rig, elevator, spider, derrick, tubular handler, tubular manipulator, tubular rotator, top drive, mouse hole, powered mouse hole, or floor; wherein the sensing apparatus is in communication with and is controlled by computer apparatus [e.g. including but not limited to, computer system(s), programmable logic controller(s) and/or microprocessor system(s)], the method further including controlling the sensing apparatus with the computer apparatus; wherein the energizing is effected by energizing apparatus in communication with and controlled by computer apparatus, the method further including controlling the energizing apparatus with the computer apparatus; wherein the signal is an identification signal identifying the member and the sensing apparatus produces and conveys a corresponding signal to computer apparatus, the computer apparatus including a programmable portion programmed to receive and analyze the corresponding signal, and the computer apparatus for producing an analysis signal indicative of accepting or rejecting the member based on said analysis, the method further including the wave-energizable identification apparatus and producing an identification signal received by the sensing apparatus, the sensing apparatus producing a corresponding signal indicative of identification of the member and conveying the corresponding signal to the computer apparatus, and the computer apparatus analyzing the corresponding signal and producing the analysis signal; wherein the computer apparatus conveys the analysis signal to handling apparatus for handling the member, the handling apparatus operable to accept or reject the member based on the analysis signal; wherein the member is a tubular member for use in well operations and the handling apparatus is a tubular member handling apparatus; wherein the tubular member handling apparatus is from the group consisting of tubular manipulator, tubular rotator, top drive, tong, spinner, downhole motor, elevator, spider, powered mouse hole, and pipe handler; wherein the handling apparatus has handling sensing apparatus thereon for sensing a signal from the wave-energizable identification apparatus, and wherein the handling apparatus includes communication apparatus in communication with computer apparatus, the method further including sending a handling signal from the communication apparatus to the computer apparatus corresponding to the signal produced by the wave-energizable identification apparatus; wherein the computer apparatus controls the handling apparatus; wherein the member is a tubular member and wherein the sensing apparatus is connected to and in communication with a tubular inspection system, the method further including conveying a secondary signal from the sensing apparatus to the tubular inspection system, the secondary signal corresponding to the signal produced by the wave-energizable identification apparatus; and/or wherein the signal produced by the wave-energizable identification apparatus identifies the tubular member.
The present invention, therefore, in at least certain aspects, provides a method for handling drill pipe on a drilling rig, the drill pipe comprising a plurality of pieces of drill pipe, each piece of drill pipe comprising a body with an externally threaded pin end spaced-apart from an internally threaded box end, the body having a flow channel therethrough from the pin end to the box end, radio frequency identification apparatus with integrated circuit apparatus and antenna apparatus within the pin end of the body, and the antenna apparatus encircling the pin end, the method including energizing the radio frequency identification apparatus by directing energizing energy to the antenna apparatus, the radio frequency identification apparatus upon being energized producing a signal, positioning each piece of drill pipe adjacent sensing apparatus, and sensing with the sensing apparatus a signal produced by each piece of drill pipe's radio frequency identification apparatus. Such a method may include one or some (in any possible combination) of the following: wherein the sensing apparatus is in communication and is controlled by computer apparatus and wherein the radio frequency identification apparatus produces an identification signal receivable by the sensing apparatus, and wherein the sensing apparatus produces a corresponding signal indicative of the identification of the particular piece of drill pipe, the corresponding signal conveyable from the sensing apparatus to the computer apparatus, the method further including controlling the sensing apparatus with the computer apparatus; wherein the energizing is effected by energizing apparatus in communication with and controlled by computer apparatus, the method further including controlling the energizing apparatus with the computer apparatus; wherein the signal is an identification signal identifying the particular piece of drill pipe and the sensing apparatus conveys a corresponding signal to computer apparatus, the computer apparatus including a programmable portion programmed to receive and analyze the corresponding signal; and/or the computer apparatus for producing an analysis signal indicative of accepting or rejecting the particular piece of drill pipe based on said analysis, the method further including the computer apparatus analyzing the corresponding signal and producing the analysis signal, and the computer apparatus conveying the analysis signal to handling apparatus for handling the member, the handling apparatus operable to accept or reject the member based on the analysis signal.
The present invention, therefore, in at least certain aspects, provides a system for handling a tubular member, the system including handling apparatus, and a tubular member in contact with the handling apparatus, the tubular member with a body with a first end spaced-apart from a second end, the first end being a pin end having a pin end recess in the first end and identification apparatus in the pin end recess, and a protector in the pin end recess protecting the identification apparatus therein; and such a system wherein the handling apparatus is from the group consisting of tubular manipulator, tubular rotator, top drive, tong, spinner, downhole motor, elevator, spider, powered mouse hole, and pipe handler.
The present invention, therefore, in at least certain aspects, provides a ring with a body with a central hole therethrough, the body having a generally circular shape, the body sized and configured for receipt within a circular recess in an end of a generally cylindrical member having a circumference, wave-energizable identification apparatus within the body, the wave-energizable identification apparatus having antenna apparatus, and the antenna apparatus extending around a portion of the body; and such a ring with sensible indicia on or in the body.
The present invention, therefore, in at least certain aspects, provides a ring with a body with a central hole therethrough, the body having a central hole therethrough the body sized and configured for receipt within a circular recess in an end of a generally cylindrical member having a circumference, identification apparatus within or on the body, and the identification apparatus being sensible indicia.
The present invention, therefore, in at least certain aspects, provides a method for making a tubular member, the method including making a body for a tubular member, the body having a first end spaced-apart from a second end, and forming a recess around the end of the body, the recess sized and shaped for receipt therein of wave-energizable identification apparatus. Such a method may include one or some (in any possible combination) of the following: installing wave-energizable identification apparatus in the recess; installing a protector in the recess over the wave-energizable identification apparatus; and/or wherein the tubular member is a piece of drill pipe with an externally threaded pin end spaced-apart from an internally threaded box end, the recess is a recess encircling the pin end, and the wave-energizable identification apparatus has antenna apparatus, the method further including positioning the antenna apparatus around and within the pin end recess.
The present invention, therefore, in at least certain aspects, provides a method for enhancing a tubular member, the tubular member having a generally cylindrical body with a first end spaced-apart from a second end, the method including forming a circular recess in an end of the tubular member, the recess sized and shaped for receipt therein of wave-energizable identification apparatus, the wave-energizable identification apparatus including antenna apparatus with antenna apparatus positionable around the circular recess.
The present invention, therefore, provides, in at least some embodiments, a member with a body, the body having two spaced-apart ends, wave-energizable identification apparatus on the exterior of the body, and encasement structure encasing the wave-energizable identification apparatus, Such a member may have one or some, in any possible combination, of the following: the encasement structure is at least one layer of heat resistant material; wherein the encasement structure is at least one layer of impact resistant material; wherein the wave-energizable identification apparatus is radio frequency identification apparatus with integrated circuit apparatus and antenna apparatus; the body has a first end spaced-apart from a second end, and at least a portion comprising a generally cylindrical portion, the generally cylindrical portion having a circumference, and the radio frequency identification apparatus positioned exteriorly on the circumference of the body; wherein the body is a pipe; wherein the pipe is a tool joint with an upset portion and the wave-energizable identification apparatus is adjacent said upset portion; wherein the body has a generally cylindrical portion which is part of an item from the group consisting of pipe, drill pipe, casing, drill bit, tubing, stabilizer, centralizer, cementing plug, buoyant tubular, thread protector, downhole motor, whipstock, mill, and torus; and/or wherein the wave-energizable identification apparatus comprises a plurality of radio frequency identification tag devices.
The present invention, therefore, provides in at least some, although not necessarily all, embodiments a method for sensing a wave-energizable identification apparatus of a member, the member as any disclosed herein with a body having two spaced-apart ends and wave-energizable identification apparatus on the body, and encasement structure encasing the wave-energizable identification apparatus, the encasement structure having at least one layer of heat resistant material, the wave-energizable identification apparatus with antenna apparatus on the body, the method including energizing the wave-energizable identification apparatus by directing energizing energy to the antenna apparatus, the wave-energizable identification apparatus upon being energized producing a signal, positioning the member adjacent sensing apparatus, and sensing with the sensing apparatus the signal produced by the wave-energizable identification apparatus. Such a method may have one or some, in any possible combination, of the following: wherein the sensing apparatus is on an item from the group consisting of rig, elevator, spider, derrick, tubular handler, tubular manipulator, tubular rotator, top drive, mouse hole, powered mouse hole, or floor; wherein the sensing apparatus is in communication with and is controlled by computer apparatus, the method including controlling the sensing apparatus with the computer apparatus; wherein the energizing is effected by energizing apparatus in communication with and controlled by computer apparatus, the method including controlling the energizing apparatus with the computer apparatus; wherein the signal is an identification signal identifying the member and the sensing apparatus produces and conveys a corresponding signal to computer apparatus, the computer apparatus including a programmable portion programmed to receive and analyze the corresponding signal, and the computer apparatus for producing an analysis signal indicative of accepting or rejecting the member based on said analysis, the method further including the wave-energizable identification apparatus producing an identification signal received by the sensing apparatus, the sensing apparatus producing a corresponding signal indicative of identification of the member and conveying the corresponding signal to the computer apparatus, and the computer apparatus analyzing the corresponding signal and producing the analysis signal; wherein the computer apparatus conveys the analysis signal to handling apparatus for handling the member, the handling apparatus operable to accept or reject the member based on the analysis signal; wherein the member is a tubular member for use in well operations and the handling apparatus is a tubular member handling apparatus; wherein the tubular member handling apparatus is from the group consisting of tubular manipulator, tubular rotator, top drive, tong, spinner, downhole motor, elevator, spider, powered mouse hole, and pipe handler; wherein the handling apparatus has handling sensing apparatus thereon for sensing a signal from the wave-energizable identification apparatus, and wherein the handling apparatus includes communication apparatus in communication with computer apparatus, the method including sending a handling signal from the communication apparatus to the computer apparatus corresponding to the signal produced by the wave-energizable identification apparatus; wherein the computer apparatus controls the handling apparatus; wherein the member is a tubular member and wherein the sensing apparatus is connected to and in communication with a tubular inspection system, the method including conveying a secondary signal from the sensing apparatus to the tubular inspection system, the secondary signal corresponding to the signal produced by the wave-energizable identification apparatus; and/or wherein the signal produced by the wave-energizable identification apparatus identifies the tubular member.
The present invention, therefore, provides in at least certain, if not all, embodiments a method for handling drill pipe on a drilling rig, the drill pipe comprising a plurality of pieces of drill pipe, each piece of drill pipe being a body with an externally threaded pin end spaced-apart from an internally threaded box end, the body having a flow channel therethrough from the pin end to the box end, radio frequency identification apparatus with integrated circuit apparatus and antenna apparatus on the body, and encased in heat resistant material, the method including energizing the radio frequency identification apparatus by directing energizing energy to the antenna apparatus, the radio frequency identification apparatus upon being energized producing a signal, positioning each piece of drill pipe adjacent sensing apparatus, and sensing with the sensing apparatus a signal produced by each piece of drill pipe's radio frequency identification apparatus. Such a method may include, wherein the sensing apparatus is in communication and is controlled by computer apparatus and wherein the radio frequency identification apparatus produces an identification signal receivable by the sensing apparatus, and wherein the sensing apparatus produces a corresponding signal indicative of the identification of the particular piece of drill pipe, said corresponding signal conveyable from the sensing apparatus to the computer apparatus, controlling the sensing apparatus with the computer apparatus, and wherein the energizing is effected by energizing apparatus in communication with and controlled by computer apparatus, controlling the energizing apparatus with the computer apparatus, and wherein the signal is an identification signal identifying the particular piece of drill pipe and the sensing apparatus conveys a corresponding signal to computer apparatus, the computer apparatus including a programmable portion programmed to receive and analyze the corresponding signal, the computer apparatus for producing an analysis signal indicative of accepting or rejecting the particular piece of drill pipe based on said analysis, the computer apparatus analyzing the corresponding signal and producing the analysis signal, and the computer apparatus conveying the analysis signal to handling apparatus for handling the member, the handling apparatus operable to accept or reject the member based on the analysis signal.
The present invention, therefore, in at least certain aspects, provides a tool joint with a body having a pin end spaced-apart from a tube body, an upset portion, a tool joint portion between the upset portion and the pin end, and wave-energizable identification apparatus on the tube body adjacent the upset portion, the wave-energizable identification apparatus encased in heat resistant material.
FIG. 31 illustrates a system 800 according to the present invention which has an offshore drilling and/or production system 821 including a drilling conductor or riser 823 extending between subsea well equipment 825 , and a floating rig, ship, or vessel, such as, for example, a dynamically positionable vessel 827 .
The drilling riser pipe or conductor 823 has multiple riser sections 829 connected together by joints 831 and extending between a sea bottom S and the vessel 827 . A tensioning system 833 located on an operational platform 835 of the vessel 827 provides both lateral load resistance and vertical tension preferably applied to a slip or tensioning ring 839 attached to the top of the riser 823 and below a telescopic joint 841 . The telescopic joint 841 decouples the vessel 827 and riser 823 from vertical motions. The riser 823 is further connected at its distal end to a lower marine riser package (“LMRP”) 843 . The LMRP 843 is releasably yet rigidly connected to a blowout preventer (“BOP”) 845 . The BOP 845 is fixedly connected to the upper section of a wellhead 849 . The lower section of the wellhead 849 connects to a wellhead conductor 851 which extends downwardly through the subsea floor S.
Each riser section 829 has an identification assembly 810 according to the present invention with wave-energizable identification apparatus. Some or all but one of the assemblies 810 may be deleted. A lowermost riser section 829 a has two assemblies 810 (as may be true for any riser or riser section in FIG. 31 and for any riser or riser section disclosed herein).
The apparatuses 810 may be any identification apparatus disclosed herein according to the present invention.
FIG. 32A shows a riser 860 according to the present invention with three sections 860 a , 860 b and 860 c with clamp sets 862 , a top flange 863 , a bottom flange 864 , a choke line 865 a and a kill line 865 b (the lines held by the clamp sets 862 ). The lowermost section 860 c has an identification assembly 870 according to the present invention around the tubular circumference of the riser section. Optionally, the sections 860 a and 860 b have wave-energizable identification apparatuses 871 which are like any wave-energizable identification apparatus disclosed herein.
Optionally, straps 869 secure the apparatus 870 to the riser section 860 c . These straps may be made of any suitable material, e.g., but not limited to, metal (e.g. steel), fiberglass, plastic (e.g. nylon), or composite material. In one particular aspect the straps are SMART BAND™ flexible bands commercially available from HCL Fasteners UK.
FIG. 33A shows the identification apparatus 870 which has a body 872 with an interior surface 874 and an exterior surface 876 .
In one aspect, the body 872 is a single integral piece, e.g. a molded plastic part. In one aspect, (in FIGS. 33C and 33D ) the body 872 has two ends 878 a and 878 b which, initially, are spaced-apart to facilitate emplacement of the body 872 around a riser. Upon installation on a riser, the ends 878 a , 878 b are brought together and connected together, e.g. with any known connection material or structure, e.g., but not limited to, with adhesive 873 or, optionally, a screw (or screws) 879 a and/or, optionally, amounts of selectively connectable releasably cooperating fastener material 877 a connected to the end 878 a and amount 877 b connected to the end 878 b . In one aspect, as shown, the releasably cooperating fastener material overlaps and seals off a junction 875 . Optionally spaces 871 a , 871 b are provided between parts of the ends 878 a , 878 b (which as shown are stepped ends) so that a single body 872 can accommodate risers of different outer diameter; e.g., but not limited to, risers of both twenty-one inch outer diameter and of twenty-one and a half inch outer diameter.
Optionally, the body 872 has a recess or recesses 889 for receiving and positioning a strap or straps (e.g. straps 869 to secure the body 872 around a riser.
Optionally, the body 872 has one, two or more projections 882 connected thereto or, as shown in FIGS. 33A, 33B , and 33 E, formed integrally thereof. In one aspect the projection(s) are located to direct impact loads away from assemblies 890 and to absorb a force or load applied to the body adjacent a wave-energizable identifier (e.g. a tag) or identifiers embedded in the body 872 , e.g. the assemblies 890 . As shown in FIG. 33B , a recess 887 with tapered sides 887 a between the two projections 882 directs or focuses to the assemblies 890 energy transmitted to the assemblies 890 . FIGS. 40A-40B , discussed below, show various shapes and configurations for a body like the body 872 . It is within the scope of the present invention to use one, two, three, four, five, six or more identification assemblies 890 in the body 872 or in any body of any assembly according to the present invention. In one particular aspect the assemblies 890 are about six inches in length.
The assemblies 890 (any identification wave-energizable tag disclosed or referred to herein) are surrounded by the body 872 .
In one particular aspect, the body 872 is made of flexible polyurethane foam and is held on a riser with high tensile strength steel straps or with flexible nylon straps. It is within the scope of the present invention for the tag assembly 890 to include a shield around a wave-energizable apparatus, e.g. as disclosed in co-pending U.S. application Ser. No. 12/317,246 filed Dec. 20, 2008, co-owned with the present invention and fully incorporated herein for all purposes. For example, a tag 890 a with a wave-energizable apparatus 890 b may be shielded by a shield 912 with the tag 890 a in a recess 922 of the shield 912 (as shown in FIG. 34A ).
In one aspect a shield 912 is made of plastic, e.g. polyoxymethylene (e.g., in one particular aspect, Dupont DELRIN™ material). The recess 922 can be machined into the material.
In one aspect, as shown in FIG. 34D , a wave-energizable assembly 890 c is placed in a recess 922 of a shield 912 and then the shield apparatus combination is inserted into or wrapped with a tube 924 , e.g. a tube of shrink wrap material. The resulting structure is then placed on and/or taped to a riser or embedded in a body, like the body 872 . In one aspect, the shield with the assembly is wrapped with heat shrink material which encompasses a riser. In one aspect any material described herein is used for the tube and for the wrap. In one aspect crosslinked polyethylene shrink wrap material (or “XLPE”) is used. Heat is applied to the material which heats and shrinks and the is allowed to cool. One, two or more additional wrap layers can be applied.
In one aspect the shield with the wave-energizable apparatus is set on a riser or a body like the body 872 and material is wrapped around the shield to connect the shield and its wave-energizable apparatus riser or the body.
A shield (like the shield 912 ) according to the present invention can be of any desired cross-sectional shape and a wave-energizable apparatus can be of any desired cross-sectional shape (or encasing material around such an apparatus can be of any desired shape). FIG. 35 illustrates shields 912 a , 912 b , 912 c , 912 d and 912 e of different cross-sectional shapes with wave-energizable apparatuses, respectively, 910 a , 910 b , 910 c , 910 d , 910 e , and 910 f of different cross-sections. One shield may house multiple wave-energizable apparatuses.
FIG. 36 shows shields 912 f , 912 g , 912 h and 912 i with, respectively, recesses 922 f , 922 g , 922 h and 922 i for housing a wave-energizable apparatus. A wave-energizable apparatus may be held in a shield recess by a friction-fit and/or with adhesive. Optionally a shield recess may have holding lips like the lips 9221 of the shield 912 h and the lips 922 m of the shield 912 i.
According to the present invention an energizable identification apparatus can be applied to, connected to, or disposed on a member using a solid mass within which is located the energizable identification apparatus (e.g., but not limited to, a mass as disclosed in pending U.S. application Ser. No. 12/317,246 filed Dec. 20, 2008). FIG. 37 shows a mass 951 of material within which is an energizable identification apparatus 959 . The mass 951 (and the masses 1141 and 1151 ) is sized and configured for insertion into a recess, notch, hollow, space, channel or opening of a riser or riser section, or it can be connected and/or strapped thereon. The mass 951 can be held in place with a friction fit and/or adhesive, glue, welding, and/or tape and/or with a body like the body 872 . The material of the mass 951 (and the masses 1141 and 1151 ) can be metal, plastic, composite, wood, ceramic, cermet, gel, aerogel, silica aerogel, fiberglass, nonmagnetic metal, or polytetrafluoroethylene. The material can be rigid and relatively unbending or it can be soft and/or flexible. An enlarged end 951 a of the mass 951 is optional.
FIG. 38 shows a mass 1151 (made, e.g. of any material mentioned for the mass 951 ) with an energizable identification apparatus 1159 therein. The energizable identification apparatus 1159 has an antenna 1158 extending from the energizable identification apparatus 1159 and disposed within the mass 1551 . With a flexible or sufficiently non-rigid mass 1151 (and with the mass 951 ) a slit or recess 1157 of any desired length within the mass 1151 may be provided for inserting the energizable identification apparatus 1159 and antenna 1158 into the mass 1151 and/or for removable emplacement of the energizable identification apparatus 1159 .
FIG. 39 shows a mass 1141 (e.g. like the masses 951 , 1151 and made of the materials mentioned above) with an energizable identification apparatus 1142 therein (or it may, according to the present invention, be thereon). The mass 1141 has a recess 1143 sized, located, and configured for receipt therein of a part or a portion of a riser, riser section or body like the body 872 to facilitate installation of the mass 1141 . A friction fit between the mass 1141 and a part or portion can hold the mass 1141 in place and/or connectors, fasteners and/or adhesive may be used to hold the mass 1141 in place.
FIG. 40A shows a riser identification assembly 1160 according to the present invention (like the assembly 870 in general shape and configuration as shown in FIG. 33A ) with a body 1162 having a projection 1163 . The projection 1163 has two spaced-apart recesses 1164 for receiving and holding straps (like the straps 869 ). A portion 1163 a of the projection 1163 is over (as viewed in FIG. 40A ) a wave-energizable apparatus 1165 . The recesses 1164 are located so that they are not over the apparatus 1165 .
FIG. 40B shows a riser identification assembly 1170 (like the assembly 870 in general shape and configuration as shown in FIG. 33A ) with a body 1172 having a projection 1173 partially over a wave-energizable apparatus 1175 . A strap 1176 resides partially in a recess 1174 over the apparatus 1175 . In one aspect according to the present invention the strap 1176 does not project beyond an exterior surface of the projection (as may any strap herein be sized and located). In another aspect, as shown in FIG. 40B , the strap 1176 (as may any strap herein project beyond a recess and/or a surface) projects beyond an exterior surface of the projection 1173 . In one aspect the strap 1176 is wider than the apparatus 1175 .
FIG. 40C shows a riser identification assembly 1180 with a body 1182 having two strap recesses 1184 and a projection 1186 . The projection 1186 may be, as shown, wider than a wave-energizable apparatus 1185 within a shield 1187 (any shield disclosed herein may be used).
Any wave-energizable apparatus used with any riser identification assembly according to the present invention may contain information (to include information and/or data) which includes some or all of: riser identification; design data for the riser; history of use of the riser; metallurgy of the riser; installation procedures; test information; quality control information; and/or manufacturing process information. Such information is conveyable to: a control system or control systems, all personnel, including, but not limited to, rig operator(s), controller(s) on site and/or off site, and/or driller(s), on-site and/or off-site. When a riser with one or more identification assemblies is removed from a location of installation, the wave energizable apparatus or apparatuses is (are) scanned and personnel and/or a control system and/or connected systems are notified of the removal and any pertinent data regarding the removal and/or the use can be entered into the wave-energizable apparatus or apparatuses). A control system (e.g. the driller system and/or a remote system) can then automatically request any required user actions and/or inputs (e.g. actions: photograph the riser, clean the riser, photograph the riser again; e.g. inputs: visual observations of the riser, producing a description (written, oral, etc.) of the used riser, and/or comments describing key aspects of the riser use and/or removal). Actual data and information from the use can be recorded automatically (e.g., in a driller system and/or a control system) and recorded into the wave-energizable apparatus or apparatuses. Any, some, or all such data can be recorded in any wave-energizable apparatus associated with a riser.
The present invention, therefore, provides in at least certain, if not all, embodiments a member with a body, the body having an exterior surface and two spaced-apart ends, wave energizable identification apparatus on the exterior surface of the body, the wave energizable identification apparatus wrapped in fabric material, the fabric material comprising heat-resistant non-conducting material, the wave energizable identification apparatus wrapped and positioned on the body so that the wave energizable identification apparatus does not contact the body, and the member is a riser. Such a method may have one or some, in any possible combination, of the following: the fabric material is at least one layer of material wrapped around the wave energizable identification apparatus; the wave energizable identification apparatus and the fabric material in which the wave energizable identification apparatus are wrapped is heat shrink material; and/or wherein the wave energizable identification apparatus is radio frequency identification apparatus with integrated circuit apparatus and antenna apparatus.
The present invention, therefore, provides in at least certain, if not all, embodiments a riser including: a riser body having an interior surface, an exterior surface, and two spaced-apart ends; at least one identification assembly (or a plurality) on the riser body; the identification assembly having an assembly body and a wave energizable apparatus in the body; the assembly body having an interior surface, an exterior surface, and a channel therethrough in which is positioned part of the riser body; the assembly body releasably secured on the riser body; and the wave energizable apparatus positioned within the assembly body. Such a method may have one or some, in any possible combination, of the following: wherein the assembly body has two ends, the two ends connected together; wherein the two ends of the assembly body are connected together by one of adhesive, fastener, and releasably cooperating fastener material; wherein the assembly body has at least one recess (or at least two or two) for a strap; wherein a strap is within the at least one recess, the strap securing the identification assembly to the riser body; wherein the assembly body has at least one projection projecting therefrom; wherein the wave-energizable apparatus is shielded by a shield within the assembly body; wherein the at least one projection is a first projection positioned over the wave-energizable apparatus; wherein a strap is within the at least one recess, the strap securing the identification assembly to the riser body and wherein the strap has a portion that projects out of the at least one recess over the wave-energizable apparatus; a recess in the assembly body adjacent the identification assembly for direction energy for energizing the wave-energizable apparatus to the wave-energizable apparatus; wherein the wave-energizable apparatus includes information regarding the riser; and/or wherein the information includes information regarding at least one of (or some of, or all of): riser design information, riser identity information, riser use information, riser installation information, riser test information, riser quality control information, riser observation information;
The present invention, therefore, provides in at least certain, if not all, embodiments a riser with a riser body having an interior surface, an exterior surface, and two spaced-apart ends; a plurality of identification assemblies on the riser body; each of the plurality of identification assemblies having an assembly body and a plurality of wave energizable apparatuses in the body; each assembly body having an interior surface, an exterior surface, and a channel therethrough in which is positioned part of the riser body; each assembly body releasably secured on the riser body; each wave energizable apparatus positioned within an assembly body; each assembly body having two ends, the two ends connected together; the two ends of each assembly body connected together by one of adhesive, fastener, and releasably cooperating fastener material; each assembly body having at least one recess for a strap; a strap within the at least one recess, the strap securing the identification assembly to the riser body; and each assembly body having at least one projection projecting therefrom.
The present invention, therefore, provides in at least certain, if not all, embodiments a riser identification assembly for securement to a riser, the riser having a riser body around which the riser identification assembly is securable, the riser identification assembly including: an assembly body securable around a riser, and a wave-energizable apparatus within the assembly body, the wave energizable apparatus including information about the riser; and, in some aspects, wherein the assembly body has two ends, the two ends connected together by one of adhesive, fastener, and releasably cooperating fastener material, and wherein the assembly body has at least one recess for a strap forcing the riser identification assembly to a riser.
The present invention, therefore, provides in at least certain, if not all, embodiments a method for identifying a riser, the riser having a riser body, the method including: activating a wave-energizable apparatus that is releasably secured within an identification assembly, the identification assembly secured around the riser body; and reading identity information from the wave-energizable apparatus to identify the riser.
In conclusion, therefore, it is seen that the present invention and the embodiments disclosed herein and those covered by the appended claims are well adapted to carry out the objectives and obtain the ends set forth. Certain changes can be made in the subject matter without departing from the spirit and the scope of this invention. It is realized that changes are possible within the scope of this invention and it is further intended that each element or step recited in any of the following claims is to be understood as referring to the step literally and/or to all equivalent elements or steps. The following claims are intended to cover the invention as broadly as legally possible in whatever form it may be utilized. The invention claimed herein is new and novel in accordance with 35 U.S.C. §102 and satisfies the conditions for patentability in §102. The invention claimed herein is not obvious in accordance with 35 U.S.C. §103 and satisfies the conditions for patentability in §103. This specification and the claims that follow are in accordance with all of the requirements of 35 U.S.C. §112. The inventors may rely on the Doctrine of Equivalents to determine and assess the scope of their invention and of the claims that follow as they may pertain to apparatus not materially departing from, but outside of, the literal scope of the invention as set forth in the following claims. All patents and applications identified herein are incorporated fully herein for all purposes. It is the express intention of the applicant not to invoke 35 U.S.C. §112, paragraph 6 for any limitations of any of the claims herein, except for those in which the claim expressly uses the words ‘means for’ together with an associated function. In this patent document, the word “comprising” is used in its non-limiting sense to mean that items following the 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 of the elements.
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A riser having a riser body having an interior surface, an exterior surface, and two spaced-apart ends, at least one identification assembly on the riser body, the identification assembly having an assembly body and a wave energizable apparatus in the body, the assembly body having an interior surface, an exterior surface, and a channel therethrough in which is positioned part of the riser body, the assembly body releasably secured on the riser body, and the wave energizable apparatus positioned within the assembly body. This abstract is provided to comply with the rules requiring an abstract which will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure and is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims, 37 C.F.R. 1.72(b).
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RELATED APPLICATIONS
The subject matter of this application is related to applications RTE-RESPONSIVE PACEMAKER WITH NOISE-REJECTING MINUTE VOLUME DETERMINATION, Ser. No. 08/848,968 filed on May 2, 1997 RATE-RESPONSIVE PACEMAKER WITH MINUTE VOLUME DETERMINATION AND EMI PROTECTION, Ser. No. 08/850,529 filed on May 2, 1997, RATE-RESPONSIVE PACEMAKER WITH EXERCISE RECOVERY USING MINUTE VOLUME DETERMINATION, Ser. No. 08/850,692 filed on May 2, 1997.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to rate-responsive pacemakers and, more particularly, to pacemakers that employ a minute volume metabolic demand sensor as a metabolic rate indicator, said sensor having a fast response time to thereby insure that the pacemaker reacts quickly and accurately to changes in the level of activity of a patient such as, for example, onset of exercise.
2. Description of the Prior Art
Many attempts have been made to control the heart rate of a pacemaker patient so that it will duplicate the intrinsic heart rate of a healthy person both when the patient is at rest and when the patient is involved in various levels of exercise. Metabolic demand related parameters heretofore proposed for controlling the pacing rate include the QT interval, respiration rate, venous oxygen saturation, stroke volume, venous blood temperature, and minute volume or ventilation, among others. (The terms minute ventilation and minute volume are used interchangeably). In addition, the use of mechanical and electrical sensors which detect patient motion have also been explored in such attempts at achieving improved rate-responsiveness.
Of the various parameters available, it has been found that pacemakers using minute volume as a parameter for controlling pacing rate are particularly advantageous. However, a problem with these types of pacers has been that the means of converting this parameter into an actual metabolic indicated parameter which may be used to determine the optimal interval between pacing pulses was somewhat slow.
A further problem is that, in general, even though metabolically-related parameters used for controlling rate-responsive pacemakers, especially the tidal volume component of minute ventilation react fairly rapidly in reflecting changes in the patient's physical activity, the pacemakers' circuitry does not react with the same speed or time constant. This can result in the patient having a hemodynamic deficiency due to the lag time involved between the start of an increased level of exercise and the reaction thereto by the pacemaker.
A further problem with prior art pacemakers is that they incorporate a long term filter in the minute volume determination to determine a minute volume baseline. The filter approximates the median minute volume ventilation but its output varies during extended exercise. Therefore, extended exercise may result in an initial value which is too high or a final value which is too low.
OBJECTIVES AND SUMMARY OF THE INVENTION
In view of the above mentioned disadvantages of the prior art, it is an objective of the present invention to provide a pacemaker which dynamically responds to the instantaneous physical level of activity of a patient and adjusts its pulse rate accordingly.
A further objective is to provide a metabolic rate responsive pacemaker which is capable of generating a metabolic indicated rate parameter relatively rapidly to thereby eliminate a lag between onset of physical activity and the corresponding response or adjustment by the pacemaker.
Another objective is to provide a pacemaker which automatically tracks in the minute volume baseline and adjusts its rate response function used to map the minute volume into the metabolic indicated rate accordingly.
Other objectives and advantages of the invention shall become apparent from the following description. Briefly, a pacemaker constructed in accordance with this invention includes sensing means for sensing a metabolic demand parameter of the patient indicative of his or her instantaneous physical activity. Preferably, the metabolic demand parameter is minute volume which can be determined, for example, from impedance measurements. Minute volume has been found to be an accurate representation of the physical activity and the corresponding blood flow and oxygen demand of a patient. This parameter is converted into a corresponding metabolic indicated rate (MIR), which rate may be used to define the interval between the pacer pulses. The mapping of minute volume to metabolic indicated rate (MIR), preferably, uses a preselected curve which may be, for example, an exponential curve, or other monotonic curves. In one embodiment of the invention, the minute volume is determined using a breath by breath computation. In another embodiment the minute volume is determined by taking a derivative of the tidal volume. The resulting rate is then used to calculate a optimal paced pulse interval.
It should be understood that rate responsive systems making use of the minute volume as a parameter first calculate a long term average for the minute volume of a patient and then determine the difference between this long term average and an instantaneous minute volume obtained as described below. The resulting differential parameter is referred to as "the minute volume" for the sake of brevity. However, in the drawings, the parameter is identified as dmv or delta MV to indicate that, in fact, this parameter corresponds to the variation of the instantaneous minute volume from a long term average value.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a block diagram of a pacemaker constructed in accordance with this invention;
FIG. 2 shows a block diagram of the pace and sense circuit for the pacemaker of FIG. 1;
FIG. 3 shows a block diagram of a microprocessor for the pacemaker of FIG. 2;
FIG. 4 shows details of the controller for the microprocessor of FIG. 3;
FIG. 5 shows details of the minute volume processor for the controller of FIG. 4;
FIG. 6 shows a block diagram for the circuit used to determine thoracic impedance;
FIG. 7 shows details of the circuitry used to convert the thoracic impedance into a corresponding differential minute volume;
FIG. 7A shows a flow-chart for the circuit of FIG. 7 for determining a zero crossing;
FIGS. 8A and 8B show flow charts for determining a first delta minute volume;
FIG. 9 shows an exponential mapping function mapping dmv in to MIR;
FIG. 10 shows a block diagram for circuit 110 in FIG. 5 for obtaining the MV gain and baseline;
FIG. 11 shows graphs for cumulative percentiles used by the fuzzy logic circuit of FIG. 10;
FIGS. 12A, B and C show the input membership function for obtaining the auto RRF fuzzy logic circuit 286 of FIG. 10;
FIG. 13 shows the block diagram of an alternate embodiment for obtaining the minute ventilation;
FIGS. 14A-B show various waveforms characteristic of the circuit of FIG. 13 for the thoracic impedance, limiter output and adaptive filter output, respectively, and FIGS. 15A-D show characteristic waveshapes for the circuit of FIG. 13 for the differentiation input and output, absolute value and low pass filter.
DETAILED DESCRIPTION OF THE INVENTION
Details of a pacemaker in accordance with the present invention are shown in FIGS. 1-6. FIG. 1 shows a block diagram of the pacemaker. The pacemaker 10 is designed to be implanted in a patient and is connected by leads 12 and 13 to a patient's heart 11 for sensing and pacing the heart 11 as described for example in U.S. Pat. No. 5,441,523 by T. Nappholz, entitled FORCED ATRIOVENTRICULAR SYNCHRONY CHAMBER PACEMAKER, and incorporated herein by reference. Briefly, the atrial cardiac lead 12 extends into the atrium of the heart 11 and the ventricular cardiac lead 13 extends into the ventricle of the heart 11. Leads 12 and 13 are used for both sensing electrical activity in the heart and for applying pacing pulses to the heart. The pacemaker 10 includes a pace and sense circuit 17 for the detection of analog signals from leads 12 and 13 and for the delivery of pacing pulses to the heart; a microprocessor 19 which, in response to numerous inputs received from the pace and sense circuit 17, performs operations to generate different control and data outputs to the pace and sense circuit 17; and a power supply 18 which provides a voltage supply to the pace and sense circuit 17 and the microprocessor 19 by electrical conductors (not shown). The microprocessor 19 is connected to a random access memory/read only memory unit 81 by an address and data bus 122. A low power signal line 84 is used to provide to the microprocessor 19 a logic signal indicative of a low energy level of the power supply 18. The microprocessor 19 and the pace and sense circuit 17 are connected to each other by a number of data and control lines including a communication bus 42, an atrial sense line 45, an atrial pacing control line 46, an atrial sensitivity control bus 43, an atrial pace energy control bus 44, a ventricular sense line 49, a ventricular pace control line 50, a ventricular sensitivity control bus 47, and a ventricular pacing energy control bus 48.
FIG. 2 shows details of the pace and sense circuit 17. The circuit 17 includes an atrial pacing pulse generator 24, a ventricular pacing pulse generator 34, an atrial heartbeat sensor 25, a ventricular heartbeat sensor 35, and a telemetry circuit 30. The preferred embodiment of the pace and sense circuit 17 also includes an impedance measurement circuit 14 for measuring a physiological parameter indicative of the patient's metabolic demand. The pace and sense circuit 17 also includes a control block 39 which is interfaced to the microprocessor 19.
In operation, the atrial and ventricular heartbeat sensor circuits 25 and 35 detect respective atrial and ventricular analog signals 23 and 33 from the heart 11 and convert the detected analog signals to digital signals. In addition, the heartbeat sensor circuits 25 and 35 receive an input atrial sense control signal on a control bus 27 and an input ventricular sense control signal on a control bus 37, respectively, from the control block 39. These control signals are used to set the sensitivity of the respective sensors.
The atrial pacing pulse generator circuit 24 receives from the control block 39, via an atrial pacing control bus 28, an atrial pace control signal and an atrial pacing energy control signal to generate an atrial pacing pulse 22 at appropriate times. Similarly, the ventricular pacing pulse generator circuit 34 receives from the control block 39, via a ventricular pacing control bus 38, a ventricular pace control signal and a ventricular pacing energy control signal to generate a ventricular pacing pulse 32. The atrial and ventricular pace control signal determine the respective timing of atrial and ventricular pacing that take place, while the atrial and ventricular pacing energy control inputs determine the respective magnitudes of the pulse energies.
The pacemaker 10 makes an impedance measurement when the microprocessor 19 sends a signal on the impedance control bus 21 to activate the impedance measurement circuit 14. The impedance measurement circuit 14 then applies a current to the ventricular cardiac lead 13 via lead 20 and measures a voltage resulting from the applied current, as discussed in more detail below. These current and voltage signals define an impedance characteristic of the patient's metabolic demand, and more particularly, of the instantaneous minute volume. This instantaneous minute volume is then filtered and further modified by subtracting from it a long term average value, as discussed below. The resulting parameter is the minute volume parameter.
The telemetry circuit 30 provides a bidirectional link between the control block 39 of the pace and sense circuit 17 and an external device such as a programmer. It allows data such as the operating parameters to be read from or altered in the implanted pacemaker. An exemplary programmer is the Model 9600 Network Programmer manufactured by Telectronics of Englewood, Colo., U.S.A.
FIG. 3 shows the microprocessor 19 having a timer circuit 51 for generating several timing signals on its output ports, a controller 53, a vectored interrupts circuit 54, a ROM 55, a RAM 56, an external memory 57 and an interface port 41. Signals between these elements are exchanged via an internal communications bus 40. Timer circuits 51 generate various timing signals. The RAM 56 acts as a scratchpad and active memory during execution of the programs stored in the ROM 55 and used by the microprocessor 19. ROM 55 is used to store programs including system supervisory programs, detection algorithms for detecting and confirming arrhythmias, and programming for determining the rate of the pacer, as well as storage programs for storing, in external memory 57, data concerning the functioning of the pulse generator 10 and the electrogram provided by the ventricular cardiac lead 13. The timer circuit 51, and its associated control software, implements some timing functions required by the microprocessor 19 without resorting entirely to software, thus reducing computational loads on, and power dissipation by, the controller 53.
Signals received from the telemetry circuit 30 permit an external programmer (not shown) to change the operating parameters of the pace and sense circuit 17 by supplying appropriate signals to the control block 39. The communication bus 42 serves to provide signals indicative of such control to the microprocessor 19.
The microprocessor 19 through its port 41 receives status and/or control inputs from the pace and sense circuit 17, including the sense signals on the sense lines 45 and 49 previously described. Using controller 53, it performs various operations, including arrhythmia detection, and produces outputs, such as the atrial pace control on the line 46 and the ventricular pace control on the line 50, which determine the type of pacing that is to take place. Other control outputs generated by the microprocessor 19 include the atrial and ventricular pacing energy controls on the buses 44 and 48, respectively, which determine the magnitude of the pulse energy, and the atrial and ventricular sensitivity controls on the buses 43 and 47, respectively, which set the sensitivities of the sensing circuits. The rate of the atrial and/or ventricular pacing is adjusted by controller 53 as set forth below.
The pacemaker 10 of the present invention will function properly using any metabolic indicator rate system, so long as that system is able to reliably relate the sensed parameter to an appropriate matching of metabolic demand with the paced rate. However, the preferred embodiment of the invention employs the impedance measurement circuit 14, shown in FIG. 5, which measures the cardiac impedance to determine the respiratory minute volume as described generally in U.S. Pat. No. 4,901,725 to T. A. Nappholz, et al., issued Feb. 20, 1990 for "Minute Volume Rate-Responsive Pacemaker," incorporated herein by reference.
FIG. 4 shows the block diagram of the controller 53 of FIG. 3. The controller 53 includes a pacer 53C, which is preferably a state machine, a minute volume processor 53A and an atrial rate monitor 53B. The minute volume processor 53A uses the data supplied via the internal bus 40 and the communication bus 42 from the impedance measurement block 14 to relate the minute volume indicated by the impedance measurement to the Metabolic Rate Interval (MRI). This interval is then used by the pacer 53C to determine the length of each interval in the timing cycle. While the pacemaker 10 is preferably operating in a DDD mode, it should be understood that it can operate in other modes as well. The atrial rate monitor 53B generates an Automatic Mode Switching (AMS) signal upon detection of a nonphysiological atrial rate and rhythm. This AMS signal automatically switches the pacemaker 10 to a non-atrial-tracking mode under certain conditions. When a physiological atrial rate resumes, the AMS signal is deactivated and the pacemaker returns to an atrial tracking mode.
Referring now to FIG. 5, impedance measurement circuit 14 includes a thoracic impedance sensor 100 which is coupled by connection 20 to one of the patient's leads, such as lead 13. The sensor 100 generates a time-dependent signal ti indicative of the sensed thoracic impedance of the patient. The signal is fed to a delta minute ventilation (dmv) generator 102 which converts this ti signal into a corresponding dmv signal as indicated in FIG. 7 and discussed in more detail below. The signal dmv is fed to a circuit 104 which uses a conformal mapping (discussed in more detail below) to generate a corresponding metabolic indicated rate MIR1.
Signal MIR1 is fed to a paced pulse interval calculation circuit 108. The interval MRI calculated by circuit 108 is used by the state machine 53 (FIG. 4) to calculate the pacing intervals as discussed above.
Signal MIR1 is also provided to circuit 106 for computing an mv gain and a baseline parameter as discussed below.
Referring now to FIG. 6, a known thoracic impedance sensor 100 includes a current generator 120 and a high pass filter 122 coupled to one of the patient leads, such as lead 13. (It should be clear that other leads may be used as well for determining the mv parameter as described, for example, in U.S. Pat. No. 5,562,712). The lead 13 includes a tip electrode 124 and a ring electrode 126. As known in the art, at predetermined times, the current generator 120 applies current pulses between the ring electrode 126 and pacemaker case 128, and the corresponding voltage is sensed between the tip electrode 124 and case 128. Typically, each current pulse has a pulse width of about 7.5 μsec, at repetition rate of about 18 pulses per second and an amplitude of about 1 mA. This pulse repetition rate is chosen at well above twice the Nyquist sampling rate for the highest expected intrinsic heart beats, and is preferable so that it can be easily differentiable from noise induced by a power line at 50 or 60 Hz.
The sensed voltage, is passed through the high pass filter 122 selected to accept the 7.5 μsec pulses and exclude all noise signals. After filtering, the voltage signal is sampled by a sample and hold (S/H) circuit 130. Preferably the S/H circuit takes samples before the start of the test pulses from generator 120 (to enhance the effectiveness of the filter 122) as well as toward the end of the pulse duration.
The output of circuit 130 is passed through a band pass filter 132 which selects the signals in the range of normal respiration rate, which is typically in the range of 5-60 cycles/minute.
The output of the BPF 132 amplified by amplifier 134 to thereby generate the thoracic impedance signal ti. The amplifier raises the signal ti to a level sufficient so that it can be sensed and processed by the delta minute volume generator 102.
Referring to FIG. 7, circuit 102 includes an A/D converter 140, a zero crossing detector 142, a magnitude calculator circuit 146, calculator circuit 148 for calculating parameters rr, tv and dmv, and a low pass filter 150. Circuits 140 and 142 are preferably discrete hardware components while the remaining circuits 146, 148, 150 are implemented by a microprocessor, however are shown here as discrete circuits for the sake of clarity.
Within circuit 102, the thoracic impedance signal ti is first fed to an A/D converter 140 to generate a digital representation of the signal ti. This converter generates two outputs; a sign output indicating the polarity of the signal ti and a magnitude output indicating the amplitude of ti. This magnitude is of course the same as the absolute value of the signal ti.
The sign signal is fed to a zero crossing detector 142 which generates a zero crossing indicating output whenever it detects a sign change of signal ti. Associated with detector 142 is a memory 144 for storing the polarities of the last N samples from converter 140. N may be for example 15.
Preferably the zero crossing detector 142 is implemented so that it adapts to changes in the heart rate. This feature was found to improve the rejection of cardiac stroke volume artefact and other noise sources. More specifically, the zero crossing circuit detector 142 detects a zero crossing each time more than m of n successive samples have a sign opposite to the sign value which was detected at a previous zero crossing. The values m and n are adjusted according to the paced or sensed pulse rate. This insures that the zero crossing cannot be detected at the heart rate, but can be detected at lower rates. This feature is especially beneficial for pediatric patients who have a much higher respiration rate than older patients. These higher rates can be tracked more efficiently by the present zero crossing detector 142.
The operation of the zero crossing detector 142 is shown in FIG. 7A and is now described.
Assume that at a particular instance in time t=0, a sample is converted by A/D converter 140. This sample has a sign S j which is either positive or negative and the zero crossing detector 142 must determine whether this sample corresponds to, or indicates, a zero crossing. This function is accomplished as follows. In step 200, the parameters m and n are calculated from the last N samples (whose sign S i has been stored in memory 143) using the formulas:
m=max(2,min(10,ceil(psi/dt)));
n=floor(1.5*m)
where
psi/dt=the ratio of the paced or sensed interval to the sampling interval. A typical sampling interval is about 47 msecs.
The operation `ceil` refers to rounding up to the nearest integer.
The operation `floor` refers to rounding down to the nearest integer.
In step 202 the sign S j of latest sample is stored in memory 144 and the value of the oldest sample S j-n is discarded.
In step 206 a test is performed to check if the last zero-crossing referred to positive or negative crossing was positive. If the last crossing (indicated by a latch) was positive then in step 206 the number of negative sample values in the memory 144 from the least n samples is counted. In step 210, the count is compared to m. If count>m then in step 212 all the values in the polarity memory 144 are changed to negative.
In steps 220-226 a similar process is followed for a negative latch value.
If in steps 210 and 222 count<m, then signal S j does not indicate a zero crossing. Otherwise, at the end of steps 214 or 226, a zero crossing is indicated by circuit 142.
The zero crossing signal is sent to the compute circuit 144 (FIG. 7). The magnitude of the ti sample is also fed to the compute circuit 144 by A/D converter 140.
The magnitude calculation circuit 146 sums and stores the magnitude values (as shown in detail in FIG. 8A) for further processing in the compute circuit 148. The compute circuit 148 calculates an instantaneous minute volume (mv), tidal volume (tv) and respiration rate (rr) parameter every 1.5 seconds as shown in FIG. 8B. At least one full breath is included in each calculation to reduce the variability of the results. The various intermediate variables discussed below remain unchanged from one calculation to the next.
Referring first to the flow chart of FIG. 8A, first, in step 250, variable t1 is tested to see if it is longer than 12 seconds. This variable t1 is in effect a timer. If t1 is longer than 12 seconds, then a jump is made to step 254. Otherwise, in step 252 the variable s1 is incremented by the magnitude of the latest sample. The variable T1 is also incremented by the sampling interval dt. (As mentioned above the sampling interval dt is about 47 msec).
In step 254 a check is performed to determine whether the zero crossing detector 142 has identified the present sample as a zero crossing by circuit 142. If `yes` then in step 256, a zero crossing counter zc1 is incremented by one, in step 258 a cumulative timer between t2 is incremented with t1 and t1 is reset to zero. In step 260 a cumulative sum s2 is incremented with s1 and the variable s1 is reset to zero. What is accomplished in FIG. 8A in effect is to perform an integration on the thoracic impedance ti. More specifically, the absolute value or magnitude of ti is integrated between the zero crossings. At each zero crossing the zero crossing counter zc1 is incremented and the cumulative time t2 and thoracic impedance values s2 are updated. The impedance values obtained during more than half of a breathing cycle are accumulated only at high respiration rates. If no zero crossings are detected for 12 seconds, the integration is interrupted (step 250) to insure that the intermediate integration variables do not overflow.
Having calculated the various intermediate variables, the calculate circuit 144 now calculates the output variables as follows (see FIG. 8B). In step 262 zc2 which is set to the old value of zc1 (i.e., prior to the performance of steps 250-260) is checked. If this variable is not zero, then in step 264 the variables rr and tv are calculated using the formulas:
rr=30*(zc1+zc2)/(t2+t3); and
tv=gain*(s2+s3)/(t2+t3).
Where s2 is the sum of the absolute values of ti between zero crossings as determined in FIG. 8A, s3 is the previous value of s2;
t2 is the time between zero crossings as determined in FIG. 8A, t3 is the previous time;
The gain is a variable determined by circuit 110 as described below.
Next, in step 266 s3 is set to s2 and s2 is reset to zero. In step 268 t3 is set to t2 and t2 is set to zero. In step 270 zc2 is set to zc1 and zc1 is set to zero.
In step 272 a first delta minute volume parameter dmv1 is determined using the formula:
dmv1=tv*rr-baseline
where the baseline parameter is also determined by the circuit 106 as described below.
If in step 262 it is determined that zc2 is zero (i.e., no zc2 parameter has been determined in the previous calculation) in step 274 a check is performed to see if a period of 12 seconds has passed without a zero crossing being detected. If `yes` then in step 276 the parameters rr and tv are reduced by a small fraction and the process continues.
In this manner, the parameters rr, tv and dmv1 are updated every 1.5 seconds if a corresponding zero crossing is detected. If no zero crossings are detected for up to 12 seconds, the values of these parameters are left unchanged. After 12 seconds without zero crossings, the values are gradually reduced toward the baseline parameter, to prevent inappropriate high rate pacing.
The procedure described above allows the pacemaker to measure respiration rate accurately, but tidal volume can be only approximated since the ratio of peak thoracic impedance to tidal volume varies from patient to patient. The gain parameter is chosen by circuit 106 so that an increase in the minute ventilation is related to the heart rate increase in a healthy patient. The following relationships approximate the relationships between heart rate hr (in BPM), tidal volume tv(in liters), and delta minute ventilation dmv (in liters per minute), based on patients having average heights and weights:
dmv=(hr-min -- hr)/1.5 and
tv=dmv/rr
where min-hr is the heart rate at rest and rr is the respiration rate in breaths per minute.
Getting back to FIG. 7, after the parameters rr, tv and dmv1 the computed delta minute ventilation dmv1 is passed through the low-pass filter 150 to smooth the results. Preferably the filter 148 is a single pole low-pass filter, which has been found to model physiological response more closely than more complex filters. The filter is implemented preferably digitally, for example by using the equations given below. In a fixed-point arithmetic implementation an accumulator (incorporated in filter 150, not shown) must have more bits of precision than the delta minute ventilation values. The accumulator range is limited to prevent the filter from exhibiting delayed response following very high or very low input values.
a=a+(dmv1-a)*(w*dt/tc).
if (a>max -- dmv)a=max -- dmv
if (a<0)a=0
where:
dmv=a
dmv1=input (unfiltered delta minute ventilation from the circuit 148)
dmv=output (filtered delta minute ventilation)
a=the sum in the filter accumulator
w=sample weight
dt=time interval between iterations, typically 1.5 seconds
tc=time constant, typically 12 seconds
max -- dmv=the value of MV which will map to max -- hr (discussed more fully below).
Optionally, the parameters rr and tr are provided to filter 148 for performing an additional cross check function, wherein these two parameters are compared to generate a confidence level regarding the dmv determination. This feature is not part of the present invention and is described in more detail in application Ser. No. 08/848,968 filed May 2, 1997 and entitled RATE RESPONSIVE PACEMAKER WITH NOISE REJECTION MINUTE VOLUME DETERMINATION.
The output then of filter 148 is the delta minute volume parameter dmv in FIG. 5. Next, this parameter dmv must be converted into a metabolic indicated rate (MIR) parameter. Schemes for performing this function are well known in the art. One such scheme is disclosed in copending application Ser. No. 08/641,223 filed Apr. 30, 1996, and its continuation, application Ser. No. 08/823,077 filed Mar. 24, 1997 entitled RATE RESPONSIVE PACEMAKER WITH AUTOMATIC RATE RESPONSE FACTOR SELECTION incorporated herein by reference. As disclosed in this reference, a curvilinear mapping between minute ventilation and MIR is preferable because it can be modeled after physiological data on a wide range of normal subjects.
More particularly, it has been found that an excellent fit can be generated if an exponential mapping function is used. One such function is shown in FIG. 9. To save computational time, the exponential function may be performed by an interpolated table look-up function. The logarithmic function used to compute max -- dmv is evaluated only by the programmer, at the time min -- hr or max -- hr is changed. The rate response factor (RRF) is defined so that one unit change in RRF relates to a 10% change in the peak value minute ventilation signal. It may be computed and displayed by the programmer, or may be entered by the user and used to initialize mv -- gain.
The mapping function of FIG. 9 is defined by the following:
MIR1=a0-a1*exp(-dmv/a2)
max -- dmv=a2*1n(a1/(a0-max -- hr)) (used by low-pass filter 148)
a0=the upper heart rate asymptote, typically about 230 ppm
a1=a0-min -- hr (a1 determines min -- hr)
a2=max -- dmv/1n(a1/a0-max -- hr) (a2 determines max -- hr)
dmv=filtered delta minute ventilation from delta mv generator 102
max -- dmv=the maximum value of dmv which is mapped to max -- hr
max -- hr=the programmed maximum value of paced heart rate
RRF=rrf -- const+1n(mv -- gain/max -- dmv)/1n(1.1)
mv -- gain=max -- dmv*1.1(RRF-rrf -- const)
rrf -- const is chosen to establish the nominal RRF value.
As indicated in FIG. 5, the parameter MIR1 is also fed to a gain and baseline calculating circuit 106. The gain and baseline circuit 106 is best implemented by fuzzy logic digital circuity illustrated in FIGS. 10 and 11. The graph of FIG. 11 illustrates a typical cumulative percentile curve for subjects in the same age and fitness class. The target heart rates (thr0, thr1) and the cumulative percentiles (p0, p1) are chosen to fall on the portion of the curve 300 which is steepest and most repeatable for most patients. Two additional curves have been drawn to illustrate the effect of underpacing (pacing at too low a rate) (302) or overpacing (pacing at too high a rate) (304). The effects of the fuzzy logic rule base is to adjust the gain and baseline over time to approximate the standard curve. Target heart rate thr2 and cumulative percentile p2 are used as a cross-check to prevent overpacing in active patients who occasionally reach peak exercise levels.
Referring now to FIG. 10, target heart rate (thr0) is the programmed minimum paced heart rate, and represents the heart rate during sleep. The percentile (p0) is the percentage of time that the paced heart rate is less than the target heart rate. Every 1.5 seconds an accumulator 280 is incremented if the paced heart rate MIR2 is less than the target heart rate. Each 90 minutes the percentile value is computed and is transferred to a buffer containing the last 24 hours of data. The average percentile over the full contents of the buffer is computed and the accumulator is reset to zero.
Target heart rate (thr1) represents the heart rate during light exercise. Its value is chosen based on statistical data for patients. The percentile (p1) is computed in the same way as (p0). Target heart rate (thr2) is the programmed maximum paced heart rate, and represents the heart rate during peak exercise. The percentile (p2) is computed in the same way as (p0).
After these three parameters p0, p1, p2 are computed, a fuzzy logic inference circuit 286 is used to determine whether the baseline and the mv gain should be incremented or decremented.
The fuzzy logic input membership functions for p0, p1 and p2 are shown in FIGS. 12A, 12B and 12C respectively. The circuit 286 makes use of the following inference rules:
R1: If p0 is LOW then increase the baseline.
R2: If p1 is HIGH then decrease the baseline.
R3: If p1 is LOW and p0 is not HIGH then decrease the gain.
R4: If p1 is HIGH and p0 is not LOW and p2 is not LOW then increase the gain.
R5: If p2 is LOW and p0 is not HIGH then decrease the gain.
The rational for these rules is that if p0, p1 or p2 is LOW then the patient is underpaced during the relevant activity, while a HIGH for the same parameters indicates that the patient is overpaced during the same exercise period.
Using these controls circuit 288 computes the MV baseline. This is performed every 90 minutes, based on the last 24 hours of data. To increase its value, a fixed fraction of max -- mv, on the order of 1/32, is added to the accumulator. To decrease its value, the same fixed fraction of max -- mv is subtracted from the accumulator. These adjustments are made additively in proportion to the truth value of each rule. The fractional value of 1/32 has been selected to allow a baseline adjustment of 50% of the full minute ventilation range over a period of one day. The rate of adjustment may be increased by decreasing the evaluation time intervals. Immediately after implant it may be desirable to allow more rapid adaptation; for instance, 15 minute intervals initially, increasing gradually to 90 minute intervals over a period of 2 days.
Similarly, the circuit 290 is used to calculate the mv gain parameter. More specifically, the gain is adjusted every 90 minutes, based on the last 24 hours of data. To increase its value, a fixed fraction of its current value, on the order of 1/128, is added to an accumulator (not shown). To decrease its value, the same fixed fraction of its current value is subtracted from the accumulator. These adjustments are made additively in proportion to the truth value of each rule. The fractional value of 1/128 has been selected to allow an effective time constant of eight days. The rate of adjustment may be increased by decreasing the evaluation time intervals. Immediately after implant it may be desirable to allow more rapid adaptation; for instance, 15 minute intervals initially, increasing gradually to 90 minute intervals over a period of eight days.
The two parameter mv gain and baseline are provided to the delta mv generator 102 (FIGS. 5, 7).
Getting back to FIG. 5, the parameter MIR1 is then used to generate a metabolic indicated rate interval (MRI) by calculator 108. The paced pulse interval is inversely related to the paced heart rate as indicated by the following equation.
ppi=60000/phr
ppi=paced pulse interval, milliseconds
phr=paced heart rate, pulses per second
Other time intervals of the pacing cycle are computed by the state machine 53C (FIG. 4) using the paced pulse interval and/or the heart rate.
An alternate embodiment of computing minute ventilation for the calculator 102 is now presented. This method is based on averaging the absolute value of the derivative of the thoracic impedance signal and, unlike the implementation shown in FIG. 7, it does not require the use of a zero-crossing detector or any measurement of respiration rate.
Briefly, any method of computing minute ventilation involves a compromise between rapidity of response and rejection of artifacts or noise. All methods include some type of low-pass filter. If the cutoff frequency of the low-pass filter is increased, the response time is faster and the sensitivity to artifacts and noise is greater. The method presented herein is computationally simpler than method and apparatus shown in FIG. 7, and could be implemented entirely in hardware if desired.
The parameter delta MV (dmv) represents the increase of minute ventilation above a baseline. The baseline is the level of minute ventilation at which the paced heart rate is equal to the programmed minimum (min -- hr). In this embodiment, minute ventilation is computed by averaging the absolute value of the derivative of the thoracic impedance signal. A cross-check function is included to reduce the effect of motion artifact.
Referring now to FIG. 13, circuit 102A for determining the dmv parameter includes several functional blocks such as an A/D converter 402, a high pass filter 404, a multiplier 406, a limiter 408, and a derivative calculator 410. Also included are an absolute value determinator 412, a summer 414, and a low pass filter 416.
Functional blocks or circuits 402-508 operate on, and generate an output for each sample of thoracic impedance ti. The remaining functional blocks or circuits 410-416 are operated at regular intervals such as every 1.5 seconds.
First the thoracic impedance parameter ti is fed to the A/D converter 402 which in response generates a digital representation of the instantaneous thoracic impedance, typically at the MV current-pulse rate.
The digital high-pass filter 404 is used to establish a constant baseline for the thoracic impedance measurement. This function may be deleted if the preceding circuits (used to generate ti) ensure a known constant baseline, or if the limiter 408 is not used. The filter 404 is implemented by using an accumulator (not shown) and performing the following equations. In a fixed-point arithmetic implementation the accumulator must have more bits of precision than the delta minute ventilation values.
a=a+(x-a)*(dt/tc)
y=x-a
where x=input digital thoracic impedance, i.e. the input of the filter 404
y=output digital thoracic impedance, i.e., the output of the filter 404;
a=content of the accumulator
dt=time interval between iterations, typically about 47 milliseconds
tc=time constant, typically about 3 seconds (fc=0.05 Hz=3.2 bpm).
The output y of filter 404 is multiplied by multiplier 406 by the gain which is a function of the Rate Response Factor (RRF) and which can be determined as set forth above, and in FIG. 10. This operation scales the thoracic impedance into a corresponding tidal volume (tv) at a physiologically consistent value.
This unfiltered tidal volume signal tv is limited to a level max -- tv, to reduce the effect of motion artifacts by limiter 408. The value of max -- tv may be set to a constant, or may be determined for an individual patient by measuring the peak value at the output of the limiter 408 while the patient is asked to take several deep breaths. The following equations describe the operation of the limiter 408:
if(tv>max -- tv) then 1out=max -- tv;
else if (tv<-max -- tv) then 1out=-max -- tv;
else 1out=tv;
tv=input to the limiter 408
1out=output of limiter 408.
The derivative of tidal volume is computed by derivative calculator 410 at regular intervals such as every 1.5 seconds. Its magnitude is proportional to minute ventilation. The derivative calculator also includes an accumulator (not shown). The following equations describe the operation of the derivative calculator 410:
dout=(di-a)/dt
a=di
di=input tidal volume, i.e., the limited tidal volume from limiter 408;
dt=iteration interval
a=the sum stored in the accumulator set to the previous value of di;
dout=output derivative of the tidal volume.
Next, the derivative of the tidal volume is fed to an absolute value determinator 412. The absolute value of the derivative is computed by this determinator 412 so that its magnitude may be averaged in the Low-Pass Filter 416.
Next, in summer 414, the baseline calculated in FIG. 5 is subtracted from the absolute value of the derivative of the tidal volume to obtain the delta minute volume.
Finally, the output of the summer 414 is fed to the low pass filter 416 so that the computed delta minute ventilation value is passed through a low-pass filter to smooth the results with the low-pass filter accumulator value being limited to fixed values of minute ventilation. The filter 416 is a single pole low-pass filter, which has been found to model physiological response more closely than more complex filters. The filter is implemented by the following equations. In a fixed-point arithmetic implementation the filter includes an accumulator which must have more bits of precision than the delta minute ventilation values. The accumulator value is limited to prevent the filter from exhibiting delayed response following very high or very low input values. The following equations describe the low-pass filter.
a=a+(dmv1-a)*(dt/tc)
if (a>max -- dmv)a=max -- dmv
else if (a<0)a=0
where dmv=a
dmv1=input (unfiltered delta minute ventilation, i.e. the output of summer 414)
dmv=output (filtered delta minute ventilation)
a=accumulator
dt=time interval between iterations, typically 1.5 seconds
tc=time constant, typically 12 seconds
max -- dmv=the value of MV which will map to max -- hr.
In this manner the parameter dmv is quickly and accurately determined by the circuitry of FIG. 13. FIGS. 14 and 15 show in analog form the intermediate signals generated therein. More specifically, FIG. 14A is the thoracic impedance, FIG. 14B shows the output of limiter 408. Similarly, FIG. 15A shows the input to derivative calculator 410 with a different waveform than FIG. 14B. FIG. 15B shows the output of derivative circuit 410, FIG. 15C shows the output of the absolute value determinator 412 and FIG. 15D shows the output of the low pass filter 416.
Although the invention has been described with reference to several particular embodiments, it is to be understood that these embodiments are merely illustrative of the application of the principles of the invention. Accordingly, the embodiments described in particular should be considered exemplary, not limiting, with respect to the following claims.
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A rate responsive pacemaker with improved response to exercise onset includes a detector for detecting a metabolic parameter indicative of the patient's metabolic demand. The metabolic demand parameter derived therefrom is analyzed either using a heart rate sensitive zero crossing detector or a derivative calculator and used to generate an optimized pacing rate.
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RELATED APPLICATIONS
This application claims priority to and is a continuation of U.S. patent application Ser. No. 09/365,917. filed Aug. 3, 1999 now U.S. Pat. No. 6,804,211.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to frame structures for communication systems and more particularly to frame structures for adaptive modulation wireless communication systems.
2. Description of Related Art
A wireless communication system facilitates two-way communication between a plurality of customer premises equipment (“CPE”) and a network infrastructure. Exemplary systems include mobile cellular telephone systems, personal communication systems (PCS), and cordless telephones. The objective of these wireless communication systems is to provide communication channels on demand between the users connected to a CPE and a base station in order to connect the user of a CPE with a network infrastructure (usually a wired-line system). In multiple access wireless schemes, the basic transmission unit is commonly frames of time. The frames are commonly divided into a plurality of time slots. The time slots of the frames may hold different kinds of data including control data and user information or data. In order to manage the use of the time slots of a frame, the time slots may be assigned or allocated to one or more CPEs. In this case, a CPE receiving or having an allocation of time slots may parse the allocation of the slots between one or more users associated with the CPE. CPEs typically communicate with a base station using a “duplexing” scheme that allows for the exchange of information in both directions of connection. In this scheme, the time slots of each frame may be allocated to data being transmitted from a base station to CPEs and to data being transmitted from CPEs to a base station.
Transmissions from a base station to a CPE are commonly referred to as “downlink” transmissions. Transmissions from a CPE to a base station are commonly referred to as “uplink” transmissions. Prior art wireless communication systems typically employ time division duplexing (TDD) to facilitate the exchange of information between base stations and CPEs where TDD is well known in the art. In TDD systems, duplexing of transmissions between a base station and associated CPEs is performed in the time domain. Further, the CPEs typically communicate with their associated base station with signals having a specific pre-defined radio frequency. In TDD systems, the bandwidth or channel of the signal is time-divided into frames having repetitive time periods or time “slots”. The time slots are employed for uplink and downlink transmissions between the base station and associated CPEs.
When a wireless system is implemented in a region, the region is commonly divided into cells with a base station located within each cell. Each base station in a cell of the wireless system ideally provides communication between CPEs located in the cell. The size or configuration of a cell is generally determined as a function of the physical location of the base station, the location of buildings and other physical obstructions within the cell. The maximum bit per symbol rate modulation scheme that may be employed with a cell may be limited due to channel interference and the implementation or modem complexity of CPEs within the cell. Channel interference may occur between adjacent time slots assigned to different CPEs within a cell due to distortion of signals between the base station in the cell and the CPEs. The signals are commonly distorted by destructive multi-path replication of the signals (where the signals are reflected off physical objects in the cell). In addition, the signals are commonly distorted by atmospheric conditions (such as rain). Thus, in order to have duplex communications between all CPEs associated with a base station in a cell, a modulation scheme having a bit per symbol rate that enables communication between all CPEs associated with the base station is selected.
It is noted, however, that the channel interference between CPEs and a base station varies for each CPE, e.g., as a function of the physical barriers between the base station and the CPE. Consequently, the maximum bit per symbol rate modulation scheme (i.e., having acceptable error rates given the channel interference) that may be used to communicate between each CPE and the base station may vary. In addition, the implementation or modem complexity of the CPEs associated with the base station may also vary where some CPEs may be able to support higher bit per symbol rate modulation schemes than others associated with the base station. Accordingly, the selection of one low bit per symbol rate modulation scheme for all CPEs where some CPEs may support a higher bit per symbol rate modulation in a cell may not maximize bandwidth utilization. The use of different or variable bit per symbol rate modulation schemes for different CPEs associated with a cell may increase bandwidth utilization. Unfortunately, variable bit per symbol rate modulation is not used for communication between base stations and associated CPEs due to its complexity. In particular, variable bit per symbol rate modulation schemes normally require complex CPE demodulators where some CPEs may already have limited implementation or modem complexity. The need thus exists for frame structures and frame construction techniques that enable variable bit per symbol rate modulation for CPEs and base stations within a cell that does not increase the complexity of CPEs. The present invention provides such a frame structure and frame construction techniques.
SUMMARY OF THE INVENTION
The present invention includes a method that orders or assigns downlink time slots based on the complexity of the modulation data to be stored in the downlink time slots. Preferably, the downlink time slots are sorted from the least complex modulation scheme to the most complex modulation scheme. In one embodiment, the method assigns portions of at least two downlink time slots to at least two receiving units where the modulation scheme employed by the at least two units may vary. The method first determines the complexity of the modulation scheme employed by the at least two units. Then the method assigns portions of the at least two time slots to the at least two units based on the complexity of the modulation scheme they employ. As noted, ideally, portions of the at least two downlink time slots are assigned from the least complex modulation scheme to the most complex modulation scheme. In other embodiments, the method may first order the at least two units as a function of the complexity of the modulation scheme they employ. Then this method may assign portions of the at least two time slots based on the order of the at least two units.
The method may further order uplink time slots of a frame based on the complexity of the modulation data to be stored in the uplink time slots. Preferably, the uplink time slots are also sorted from the least complex modulation scheme to the most complex modulation scheme. In one embodiment, the method assigns at least two uplink time slots to at least two transmitting units where the modulation scheme employed by the at least two transmitting units may vary. The method first determines the complexity of the modulation scheme employed by the at least two transmitting units. Then the method assigns the at least two time slots to the at least two transmitting units based on the complexity of the modulation scheme they employ. As noted, ideally, the at least two uplink time slots are assigned from the least complex modulation scheme to the most complex modulation scheme. In other embodiments, the method may first order the at least two transmitting units as a function of the complexity of the modulation scheme they employ. Then this method may assign the at least two uplink time slots based on the order of the at least two transmitting units.
The present invention also includes a method that orders downlink time slots based on the bit per symbol rate of the modulation scheme employed to generate the data to be stored in the downlink time slots. Preferably, the downlink time slots are sorted from the lowest bit per symbol rate modulation scheme to the highest bit per symbol rate modulation scheme. In one embodiment, the method assigns portions of at least two downlink time slots to at least two receiving units where the bit per symbol rate modulation scheme employed by the at least two units may vary. The method first determines the bit per symbol rate of the modulation schemes employed by the at least two units. Then the method assigns portions of the at least two time slots to the at least two units based on the bit per symbol rate modulation schemes they employ. As noted, ideally, portions of the at least two downlink time slots are assigned from the lowest bit per symbol rate to the highest bit per symbol rate. In other embodiments, the method may first order portions of the at least two units as a function of the bit per symbol rate of the modulation schemes they employ. Then this method may assign portions of the at least two time slots based on the order of the at least two units.
The method may further order uplink time slots of a frame based on the bit per symbol rate of the modulation scheme employed to generate the data to be stored in the uplink time slots. Preferably, the uplink time slots are also sorted from the lowest bit per symbol rate to the highest bit per symbol rate. In one embodiment, the method assigns at least two uplink time slots to at least two transmitting units where the bit per symbol rate of the modulation scheme employed by the at least two transmitting units may vary. The method first determines the bit per symbol rate of the modulation scheme employed by the at least two transmitting units. Then the method assigns the at least two time slots to the at least two transmitting units based on the bit per symbol rate of the modulation scheme they employ. As noted, ideally, the at least two uplink time slots are assigned from the lowest bit per symbol rate modulation scheme to the highest bit per symbol rate modulation scheme. In other embodiments, the method may first order the at least two transmitting units as a function of the bit per symbol rate modulation scheme they employ. Then this method may assign the at least two uplink time slots based on the order of the at least two transmitting units.
The present invention also includes a method of determining the encoding Ld bits of data into a frame. The frame has a time length T and the frame is transmitted at a baud rate R. The method first determines the maximum fixed bit per symbol rate of modulation for the Ld bits of data. Then the method adds x error code bits where (R*T*Bi)/(Ld+x) is an integer where Bi is the bit per symbol rate of the modulation scheme employed. It is noted that x may have a minimum value based on a minimum block error rate. Further, the x error code bits may be Reed-Solomon encoded error bits. In other embodiments, the method may determine the maximum bit per symbol rate, Bi of modulation scheme for the Ld bits of data. Then the method may add x error code bits where (R*T*Bi)/(Ld+x) is an integer.
In a further embodiment, the method first selects a convolution ratio where the selected convolution ratio adds y convolution bits to the Ld bits of data after the convolution encoding of the Ld bits of data. Then the method adds x error code bits where (R*T*Bi)/(Ld+x+y) is an integer. It is noted that in this method the convolution ratio may be modified so that (R*T*Bi)/(Ld+x+y) is an integer. In addition, the number of x error bits may be selected so that (R*T*Bi)/(Ld+x+y) is an integer.
The present invention also includes a method for determining the modulation scheme of a frame having a plurality of downlink time slots where one of the plurality of downlink slots contains control information. In this method the modulation scheme employed to generate the modulated data for the plurality of downlink time slots may vary for each of the plurality of downlink slots. In addition, the frame may be transmitted to a plurality of units where each of the plurality of units may support a modulation scheme having a maximum complexity. This method first determines the lowest modulation complexity supported by each of the plurality of units. Then the method sets the modulation complexity of the downlink slot of the plurality of downlink slots that contains control information to the determined lowest modulation complexity.
In this method, the downlink slot of the plurality of downlink slots that contains control information may be the first downlink slot in time order of the plurality of downlink slots. In addition, the method may also determine the complexity of the modulation scheme employed to generate the modulated data for at least two units of the plurality of units. Then the method may assign at least two time slots of the plurality of time slots to the at least two units based on the complexity of the modulation scheme employed to generate the modulated data for the at least two units. The assignment to the at least two units may be from the least complex modulation scheme to the most complex modulation scheme.
The present invention also includes a method for setting the values of weights of finite impulse response filter. In this case, the filter receives symbols having variable modulation rates and stores a plurality of the symbols where each stored symbol has a corresponding weight. The method first determines when a first symbol is received having a modulation rate different than the last stored symbol. Then the method changes the value of the weight that corresponds to the first symbol based on the modulation rate of the first symbol. The method may further include receiving a second symbol having a modulation rate the same as the modulation rate of said first symbol. Followed by changing the value of the weight that corresponds to the first symbol based on the modulation rate of the first symbol. More generally, the method changes the value of the weights that correspond to the first symbol based on the modulation rate of the first symbol as the first symbol propagates through the filter.
The details of the preferred and alternative embodiments of the present invention are set forth in the accompanying drawings and the description below. Once the details of the invention are known, numerous additional innovations and changes will become obvious to one skilled in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram of an exemplary cell configuration with a base station and several CPEs associated with the cell.
FIG. 2 is a diagram an exemplary time division duplex (“TDD”) frame in accordance with the present invention.
FIG. 3 is a flowchart of an exemplary process of assigning time slots of a TDD frame in accordance with the present invention.
FIG. 4 is a flowchart of an exemplary process of simplifying the configuration of data to be inserted into a TDD frame in accordance with the present invention.
FIG. 5 is a block diagram of an exemplary transmitter for use with the present invention.
FIG. 6 is a block diagram of an exemplary receiver for use with the present invention.
FIG. 7 is a block diagram of a prior art Finite Impulse Response (“FIR”) filter suitable for use with the present invention.
FIGS. 8A to 8F are diagrams illustrating a method of the invention that changes weights of a FIR filter as new symbols propagate through the filter.
Like reference numbers and designations in the various drawings indicate like elements.
DETAILED DESCRIPTION OF THE INVENTION
Throughout this description, the preferred embodiment and examples shown should be considered as exemplars, rather than as limitations on the present invention.
The present invention includes an improved frame structure and a process of generating a frame structure for use in wireless communication systems employing adaptive modulation. Adaptive modulation includes varying the bit per symbol rate modulation scheme or modulation complexity of signals transmitted between a CPE and a base station as a function of channel interference of the signals or implementation or modem complexity of the CPE. FIG. 1 is a diagram of an exemplary cell 10 that includes a base station 20 located centrally in the cell 10 and a plurality of CPEs 30 , 32 , 34 , 36 , 38 associated with the base station. FIG. 1 does not shown buildings or other physical obstructions (such as trees or hills, for example), that may cause channel interference between signals of the CPEs.
As described above, the maximum bit per symbol rate modulation scheme or technique or most complex modulation scheme selected for use in the cell 10 is normally determined as a function of the channel interference between CPEs and the implementation or modem complexity of the CPEs. As also described above, the selection of a single maximum bit per symbol rate modulation technique based on the lowest bit per symbol rate modulation scheme supported by all CPEs may not optimize bandwidth utilization within the cell 10 . In particular, lower channel interference between some CPEs (such as units 38 , 30 for example), may permit the use of a higher bit modulation technique or more complex modulation scheme that has an error level below the maximum desirable error level. Adaptive bit-rate modulation or variable bit-rate modulation between different CPEs, however, usually requires complex transmitters and receivers in the CPEs where the CPEs may already have limited implementation or modem complexity.
As noted above, the frame structure is divided into a plurality of downlink and uplink slots. Each downlink time slots may be used to store data to be received by a number of users where a user identifies their data by an address or other label. Uplink time slots are commonly assigned to individual users for transmission of data from the user to another user or system via the base station. To maximize bandwidth utilization and minimize modulator complexity in the base station and associates CPEs, the present invention simplifies the configuration of data to inserted into the time slots. Briefly, data blocks are ideally parsed into an integer number of time slots. This process is described in detail below with reference to FIG. 4 . Second, the present invention, orders or sorts the placement of data in the downlink and uplink time slots are a function of modulation complexity or bit per symbol rate modulation scheme employed to generate the data to be placed in the time slots. As described below with reference to FIG. 3 , this technique reduces the complexity of CPE modulators and the number of modulation scheme transitions in a frame.
FIG. 2 is diagram of an exemplary frame structure to be employed in a cell that enables adaptive bit per symbol rate modulation schemes to be employed in a frame structure without increasing the complexity of receivers and transmitters of CPEs associated with the cell and reducing the number of modulation scheme transitions within each frame. As shown in FIG. 2 , the frame 80 includes a plurality of time slots. In this example there are ten time slots where the first five time slots contain downlink data 82 (from the base station 10 ), and the remaining five time slots contain uplink data 84 (to the base station 10 from a CPE). In this example, the downlink slots have a modulation bit per symbol rate of DM 1 , DM 2 , DM 3 , and DM 4 where the four downlink time slots are assigned to at least four CPEs where the CPEs will retrieve data located in these slots based on their respective assignment. It is noted that many CPEs may be assigned to any one downlink time slot where each CPE retrieves its data from such a slot based on an address or identifier. Consequently, a CPE may only retrieve data from only a portion of a downlink time slot.
In addition, the uplink slots have a modulation bit per symbol rate of UM 1 , UM 2 , UM 3 , and UM 4 where the four uplink time slots are commonly assigned to four CPEs where the CPEs will insert data in these slots based on their respective assignment. It is noted that in some embodiments a CPE may be assigned more than one uplink slot. Further, downlink control information may be located at the start of the downlink time slots and an unreserved time slot may be located at the beginning of the uplink time slots. It is obviously desirable that any CPE associated a cell be able to retrieve data located in the downlink control information time slot regardless of the CPE's location within the cell. In addition, each CPE should be able to insert data into the unreserved uplink time slot.
As described above, in an adaptive bit per symbol rate modulation system the modulation scheme may vary for each CPE and thus for each downlink and uplink time slot. In order to minimize the complexity of CPEs and base stations employed in such a system and reduce the number modulation scheme transitions within a frame, the present invention requires that DM 1 ≦DM 2 ≦DM 3 ≦DM 4 and UM 1 ≦UM 2 ≦UM 3 ≦UM 4 . Thus, ideally, the data in the time slots is arranged from the least complex modulation scheme to the most complex modulation scheme. As noted, this technique reduces the number of modulation transitions, which may simplify the implementation of a base station using this frame structure 80 . Note this also enables the base station and CPEs to train on the least complex data, which may lower error rates.
Further, ideally the downlink control information is ideally encoded using the least complex modulation scheme of the system and the information placed in the unreserved uplink time slot is also encoded using the least complex modulation scheme of the system. This ensures that every CPE associated with the cell will be able to receive or encode information within desirable error levels. Ideally, the control information indicates where the modulation transitions occur within the frame. An exemplary process 90 of assigning time slots of frame 80 as shown in FIG. 2 is presented with reference to FIG. 3 .
As shown in FIG. 3 , the first step, 92 of the process 90 includes determining which CPEs will receive at least one time slot in the next frame. In duplex systems, as described above, a CPE receiving data in a downlink time slot may also transmit data in an uplink time slot. In other systems, such as point to multi-point or multi-cast systems, there may be more downlink time slots than uplink time slots. Then (in step 94 ) the most complex modulation scheme or maximum bit per symbol rate of the modulation scheme employed by the CPE is determined for each CPE. As stated above, the most complex modulation scheme or maximum bit per symbol rate modulation scheme may be determined as a function of channel interference of signals of a CPE and the maximum desirable error level and the implementation or modem complexity of the CPE.
In a preferred embodiment, Binary Phase Shift Keying (“BPSK”) modulation may be selected for the least complex modulation scheme. In BPSK, the bit per symbol rate, B 1 of the modulation scheme is one, i.e., each symbol represents one bit. B 1 could also be called the modulation scheme efficiency, i.e., how efficient the scheme encodes data. A Quadrature Amplitude Modulation (QAM) of four may be used for an intermediate modulation scheme. In QAM 4, the bit per symbol rate, B I of the modulation scheme is two, i.e., each symbol represents two bits. Higher quadrature amplitude modulations may be used for more complex modulation schemes, e.g., QAM 64 where the bit per symbol rate, B 1 of the modulation scheme is six, i.e., each symbol represents six bits. The modulation complexity or bit per symbol rate modulation scheme may be modified from frame to frame or remain constant for a plurality of frames for a particular CPE. Further, a CPE may select or indicate a desired modulation complexity or scheme.
Upon determination of the modulation complexity or bit per symbol rate modulation scheme to be used to encode data for each of the CPEs, in step 96 the CPEs are sorted in ascending order based on the selected modulation complexity or bit per symbol rate modulation scheme, i.e., from the lowest bit per symbol rate modulation scheme to the highest bit per symbol rate modulation scheme or least complex modulation scheme to the most complex modulation scheme. Finally, the time slots of a frame are allocated or assigned to the CPEs in their sorted order from the lowest bit per symbol rate modulation scheme to the highest bit per symbol rate modulation scheme or from the least complex modulation scheme to the most complex modulation scheme. As noted above, frames are constructed using this process to reduce the complexity of base stations and CPEs that insert or retrieve data therefrom. It is noted that even though modulation schemes may vary from CPE to CPE, the number of symbols to be transmitted in bursts is usually fixed to a predetermined number n×S for all CPEs regardless of their modulation scheme.
It is desirable to simplify the configuration of time slots given fixed bursts of a group of symbols n×S and variable modulation schemes. It is noted that the modulation of L bits generates a fixed number of symbols S where S=(L/B 1 ) and B 1 is the bits per symbol rate of the modulation scheme. To simplify time slot usage and bandwidth management, (L/B 1 ) or S is ideally an integer multiple of length of the time slot T S times the baud rate R of the frame. Thus, ideally L bits fit into an integer number of time slots T S based on the modulation scheme. Note each frame has a fixed number of time slots where the length of the frame (and thus the number of time slots) is determined a function of a maximum desirable delay T D between signal transmissions and the baud rate R (symbols transmitted per second) of the system. Accordingly for each frame the number of symbols transmitted is equal to T D *R. It is desirable that the number of symbols n×S or (L/B 1 ) is an integer multiple of the number of symbols transmitted per frame. Thus, it is desirable that the ratio (T D *R)/(L/B 1 ) is an integer. When the ratio (T D * R)/(L/B 1 ) is an integer then a fixed number of bursts of n×S symbols may be transmitted in each frame. This may simplify frame usage and bandwidth management.
In most systems, the L bits of data represent an encoded signal that includes overhead or Forward Error Correction (“FEC”) information where only L D of the L bits are pure data to be transmitted to a unit or base station. In these systems the number of data bits L D to be transmitted in a burst may be fixed, e.g., 256, 512, or 1024 bits. The FEC information commonly includes convolutional encoding bits and block codes including error correction encoding bits such as Reed-Solomon (RS(n,k)) data. In other embodiments, the convolutionally encoded data may also be interleaved prior to error encoding. Given that T D , R, and S are fixed due to system constraints and B 1 is selected as a function of channel interference and modem or implementation complexity, L is ideally modified to simplify the time slot configuration or the bandwidth management of a frame. As noted, L D may also be fixed in a system. In such a system L would be determined for each possible modulation scheme of the system. FIG. 4 is a flowchart of a preferred process 60 of configuring or determining L based on T D , R, and B 1 for the transmission of data by a unit or a base station so that frame usage is simplified.
As shown in FIG. 4 , the first step, 62 of the process 60 determines the maximum allowable delay T D of the system. As noted above, the delay T D is set equal to the largest acceptable delay between transmissions of signals between CPEs or units and the base station. In step 64 the maximum bit per symbol rate modulation scheme or most complex modulation scheme that may be employed for the transmission of the L D bits is determined or selected (the process of which was described above.) Then in step 66 a convolution ratio (x/y) is selected for the L D data bits. In some embodiments no convolutional encoding is employed. In such embodiments, the ratio of (x/y) is set to 1. The convolutional ratio (x/y) is one of the parameters that may be modified to change the number of bits required to encode the L D bits of data. At step 68 , the other variable parameter, the error encoding level is selected. A block code is used to reduce the Block Error Rate (“BER”) of the L D bits of data to a desirable level. In a preferred embodiment, a Reed-Solomon (“RS”) block code is used. The number of bits L required to encode the L D bits of data is thus set by the selection of the convolutional ratio (x/y) and the error code level.
At step 72 , the value of the ratio Z of (T D *R)/(L/B 1 ) is determined. The baud rate R is fixed, the delay T D was determined at step 62 , B 1 is determined at step 64 , and L is determined as function of the parameters selected at steps 66 and 68 . When it is determined at step 74 that the ratio Z is not integer, a different convolutional ratio (at step 66 ) or the error code level (at step 68 ) may be selected. In a preferred embodiment, the selection of the convolutional ratio and the error code level is varied as a function of the fractional remainder of the ratio Z, i.e., a convergence algorithm may be employed. As noted above, in some embodiments the convolution ratio is fixed to 1. In such embodiments, only the error code or block code level is modified. In order to ensure that the ratio Z is an integer, the number of bits used to generate the block code of data may be greater than necessary to meet the minimum BER. When at step 74 , the ratio Z is determined to be an integer, then the process is complete and the block of L bits is optimized or simplified for the modulation scheme or bit per symbol rate B 1 .
A transmitter 40 and receiver 50 that may employed to transmit and receive frames of data in accordance with the present invention is presented with reference to FIGS. 5 and 6 . FIG. 5 is a block diagram of an exemplary transmitter 40 . As shown in this FIGURE, the transmitter 40 includes a convolutional encoder 42 , block encoder 44 , M-ary Modulator 46 , frame constructor 48 , and up-converter 49 . The transmitter 40 receives the L D bits of data and encodes the data to generate L bits of data, packs the L bits of data into a frame and upconverts the frame of data to a transmission frequency. The convolutional encoder 42 and block coder 44 supply the FEC data that converts the L D bits of data into L bits of data. In particular, the convolutional encoder 42 uses the selected ratio (x/y) to encode the L D bits of data. The block coder uses the selected code level to encode the convoluted data to produce the encoded L bits of data to be transmitted to a base station or unit.
Then, the M-ary modulator converts the L bits of data into the n×S symbols based on the selected bit per symbol rate B 1 . Due to the selection of the convolution ratio and error code level, the n×S symbols can be inserted into an integer number of times slots of a frame. The frame constructor 48 ideally inserts the n×S symbols into time slots of a frame based on the process presented with reference to FIG. 3 above, i.e., in order of the modulation scheme (from least complex to the most complex modulation scheme). Up-converter 49 frequency shifts the packed frame of data to a frequency suitable for transmission between a CPE or unit and base station based on techniques known to those of skill in the art.
The receiver 50 shown in FIG. 6 converts the frequency shifted frame of data back into groups of L D bits of data. As shown in FIG. 6 , the receiver 50 includes a down-converter 59 , frame deconstructor 58 , M-ary demodulator 56 , block decoder 54 , and convolutional decoder 52 . The down-converter 59 frequency shifts the received signal back to baseband using techniques known to those of skill in the art. The frame deconstructor separates the frame into groups of n×S symbols for processing by the remaining components of the receiver 50 . When the receiver 50 is part of a subscriber unit, the frame deconstructor selects one of the groups of n×S symbols where the data is directed to the subscriber unit. Block decoder 54 decodes the n×S symbols using techniques known to those of skill in the art. Then, the convolutional decoder decodes the data to produce L D bits of data.
The techniques and systems presented above may be modified while still falling within the scope of the appended claims. For example, symbol shaping may also be employed in a preferred embodiment to avoid spectrum spillage due to possible abrupt changes in modulation schemes in a frame as described above. Symbol shaping is commonly accomplished by filtering the n×S symbols via a Finite Impulse Response (“FIR”) filter where an exemplary prior art FIR filter 60 is shown in FIG. 7 . As shown in FIG. 7 , the FIR filter 60 includes k multipliers and a summation node 66 . Symbols S are received sequentially and stored in filter taps T 0 to Tk 62 . Each multiplier 64 has a tap weight W 0 to Wk and tap T 0 to Tk associated with a symbol stored in the taps 62 . As can be seen from FIG. 7 , the FIR filter 60 generates an output, y having the form
y
=
∑
i
=
0
k
Wi
*
Ti
.
It is noted that different modulation schemes, such as different QAM schemes (QAM-4, QAM-16, QAM-64) employ different “alphabets” to represent the x symbols of the scheme. For example, QAM-4 has four different symbols, QAM-16 has sixteen different symbols and QAM-64 has sixty-four different symbols. In addition, different modulation schemes may have different gains that are applied to the symbols for transmission due to varying back-off requirements. In prior art variable modulation systems when the modulation scheme changes, the memory of the FIR filter is not normally reset while the weights W 0 to Wk are instantly changed to weights optimized for the modulation scheme or symbols of the scheme to prevent spectrum spillage.
This solution is not ideal, however, because the weights are then not optimized for the symbols in the memory (taps 62 ) of the filter that correspond to the previous modulation scheme or rate. One solution is to employ one set of weights for all modulation schemes. This solution is also not ideal, however, since the FIR filter is then not optimized for the alphabet of symbols for each modulation scheme. To prevent spectrum spillage and optimize the FIR filter 60 , the present invention changes the filter taps sequentially with each new symbol from the new modulation scheme as shown in FIGS. 8A to 8F . In particular, the weight that corresponds to the first new symbol of a new modulation scheme is modified as the first new symbol propagates through the filter 60 . In FIG. 8A , the filter weights W 0 to Wk are optimized for the modulation scheme of the symbols currently being processed by the FIR filter 60 . In FIG. 8B , the first symbol of a new modulation scheme is received in T 0 of the FIR filter 60 . At this point as shown in FIG. 8B , the present invention replaces the filter weight, W 0 associated with T 0 with a new filter weight W 0 ′ where W 0 ′ is optimized for the modulation scheme of the first new symbol stored in T 0 . Then, when the next symbol from the new modulation scheme is received and stored in T 0 and the first new symbol is shifted to T 1 , the present invention replaces the filter weight, W 1 associated with T 1 with a new filter weight W 1 ′ where W 1 ′ is also optimized for the new modulation scheme as shown in FIG. 8C . This process is repeated as shown in FIGS. 8D to 8F until all the symbols stored in the taps 62 the FIR filter 60 belong to the new modulation scheme and all the filter weights W 0 to Wk are associated with or optimized for the new modulation scheme. This technique reduces spectrum spillage while optimizing the weights employed in the FIR filter 60 to shape the symbols or varying modulation schemes.
Accordingly, it is to be understood that the invention is not to be limited by the specific illustrated embodiment, but only by the scope of the appended claims.
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The present invention is a method of simplifying the encoding of a predetermined number of bits of data into frames. The method adds error coding bits so that a ratio of the frame length times the baud rate of the frame times the bit packing ratio of the data divided the total bits of data is always an integer. The method may also convolutionally encode the bits of data so that the same equation is also always an integer.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is being filed under 35 USC 111 and 37 CFR 1.53, and claims the priority date of Sep. 1, 2004 by being a continuation of the United States patent application filed on Sep. 7, 2010, which is a continuation of U.S. patent application Ser. No. 12/702,723 and U.S. patent application Ser. No. 12/702,647, both of which were filed on Feb. 9, 2010 and both of which claim priority to U.S. patent application Ser. No. 10/931,271 that was filed on Sep. 1, 2004 and bears the title of METHOD AND SYSTEM FOR INVASIVE SKIN TREATMENT and which has now been abandoned.
FIELD OF THE INVENTION
[0002] The invention relates to methods and systems for skin treatment.
BACKGROUND OF THE INVENTION
[0003] Directed damage of the skin is used to stimulate regrowth of collagen and to improve skin appearance. A well known method of directed damage is ablating the epidermis using laser radiation having wavelengths strongly absorbed by water so as to heat the water to above boiling temperature. Typical lasers used for epidermis ablation are CO.sub.2 and Er:YAG lasers. Ablating the epidermis using RF (radiofrequency) current is described in U.S. Pat. No. 6,309,387. This treatment significantly reduces wrinkles and improves the skin appearance. The main disadvantages of skin resurfacing are the long healing period that can be over a month long and the high risk of dischromia. These disadvantages have reduced the popularity of ablative skin resurfacing in recent years.
[0004] Non-ablative skin resurfacing is based on heating of the dermis to a sub-necrotic temperature with simultaneous cooling of the skin surface. U.S. Pat. No. 5,810,801 describes penetrating the dermis with infrared laser radiation with dynamic cooling of the skin surface using a cryogen spray.
[0005] Wrinkles are created in skin due to the breakage of collagen fibers and to the penetration of fat into the dermal structure. Thus, destroying adipose cells and structure, can improve the surface structure. However, most wrinkle treatment methods target the collagen and do not have a significant effect on deep wrinkles. Radio frequency (RF) energy has been used for the treatment of the epidermal and dermal layers of the skin. For example, U.S. Pat. No. 6,749,626 describes use of RF for collagen formation in dermis. This patent describes a method for collagen scar formation. U.S. Pat. Nos. 6,470,216, 6,438,424, 6,430,446, and 6,461,378 disclose methods and apparatuses for affecting the collagen matrix using RF with special electrode structures together with cooling and smoothing of the skin surface. U.S. Pat. Nos. 6,453,202, 6,405,090, 6,381,497, 6,311,090, 5,871,524, and 6,452,912 describe methods and apparatuses for delivering RF energy to the skin using a membrane structure. U.S. Pat. Nos. 6,453,202 and 6,425,912 describe methods and apparatuses for delivering RF energy and creating a reverse temperature gradient on the skin surface. Although a non-ablative treatment is much safer and does not scar the skin tissue, the results of non-ablative treatments are less satisfactory.
[0006] A method described in U.S. patent application No. 20030216719 attempts to maintain the efficiency of ablative treatment with a shorter healing time and a lower risk of adverse effects. The device described in that patent coagulates discrete regions of the skin where the regions have a diameter of tens of micrometers and the distance between the regions is larger than the regions themselves. This treatment provides skin healing within a few days but the results are very superficial and less spectacular than with CO.sub.2 laser treatment, even after multiple treatments.
[0007] U.S. Pat. No. 6,277,116 describes a method of applying electromagnetic energy to the skin through an array of electrodes and delivery electrolyte using a microporous pad.
[0008] A device for ablation of the skin stratum corneum using RF electrodes is described in U.S. Pat. Nos. 6,711,435, 6,708,060, 6,611,706, and 6,597,946. However, the parameters of this device are optimized for the ablation of the stratum corneum so as to enhance drug penetration into the skin, and not for thermal collagen remodeling.
SUMMARY OF THE INVENTION
[0009] The present invention provides a system and method for simultaneously heating skin at a plurality of discrete regions of the skin. The invention may be used for collagen remodeling. In accordance with the invention RF energy is applied to the skin at a plurality of discrete locations on the skin. The RF energy is applied using an electrode having a plurality of spaced apart protruding conducting pins. When the electrode is applied to the skin surface, each protruding conducting pin contacts the skin surface at a different location, so that the plurality of pins contacts the skin at a plurality of discrete locations. An RF voltage is then applied to the electrode so as to generate an electric current in the skin that heats the skin to a coagulation temperature simultaneously at a plurality of discrete regions of the skin. Coagulation temperatures are typically in the range of about 60.degree. C. to about 70.degree. C.
[0010] The protruding pins may have blunt tips which do not penetrate into the skin when the electrode is applied to the skin. In this case, the discrete regions of treated skin are located at the skin surface in the epidermis. Alternatively, the pins may have sharp tips that allow the protruding pin to penetrate the skin into the dermis. In this way, the discrete regions of treated skin are located in the dermis.
[0011] In another embodiment, the protruding elements are provided with sharp tips that allow the elements to penetrate into the skin. After application of the RF current in the skin, the protruding elements are pressed into the skin and an electrical current is then generated that coagulates tissue in the vicinity of the tip of each protruding element. The mechanical properties of the skin are changed after coagulation and the protruding elements may penetrate inside the skin without excessive pressure. A pre-pulse of RF energy can be applied to the skin in order to soften the skin tissue so as to facilitate penetration of the protruding elements into the skin.
[0012] The surface of the skin may be pre-cooled and/or cooled during the treatment to avoid damage to the skin in the area between protruding elements. Skin cooling may be provided by contact cooling or by applying a pre-cooled liquid or cryogen spray.
[0013] The invention may be used in wrinkle treatment, collagen remodeling, skin tightening, loose skin treatment, sub-cutaneous fat treatment or skin resurfacing.
[0014] Thus in its first aspect, the invention provides a system for simultaneously heating a plurality of discrete skin volumes to a coagulation temperature, comprising:
(a) an applicator comprising an electrode having a plurality of spaced apart protruding conducting elements configured to contact the skin surface at a plurality of discrete locations; and (b) a controller configured to apply a voltage to the electrode so as to simultaneously heat a plurality of skin volumes to a coagulation temperature when the applicator is applied to the skin surface.
[0017] In its second aspect, the invention provides a method for simultaneously heating a plurality of discrete skin volumes to a coagulation temperature, comprising:
(a) applying an applicator to the skin surface, the applicator comprising an electrode having a plurality of spaced apart protruding conducting elements configured to contact the skin surface at a plurality of discrete locations; and (b) applying a voltage to the electrode so as to simultaneously heat a plurality of skin volumes to a coagulation temperature.
[0020] In the case when protruding part of the electrode penetrates within the skin the size of protruding elements should be small enough to avoid significant damage of the skin surface. Preferable size of protruding elements is from 10 to 200 microns and coagulation depth can be varied from 100 microns up to 2 mm for invasive electrodes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] In order to understand the invention and to see how it may be carried out in practice, preferred embodiments will now be described, by way of non-limiting examples only, with reference to the accompanying drawings, in which:
[0022] FIG. 1 shows a system for treating skin simultaneously at a plurality of discrete regions of skin, in accordance with the invention;
[0023] FIG. 2 shows an applicator for use in the system of FIG. 1 ;
[0024] FIG. 3 shows a second applicator for use in the system of FIG. 1 ; and
[0025] FIG. 4 shows a third applicator for use in the system of FIG. 1 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0026] FIG. 1 shows a system for applying RF energy to a plurality of discrete regions of skin in accordance with the invention. The system includes an applicator 13 , to be described in detail below, configured to apply RF energy simultaneously to a plurality of discrete regions of skin of an individual 22 . The applicator 13 is connected to a control unit 11 via a cable 12 . The control unit 11 includes a power source 18 . The power source 18 is connected to an RF generator 15 that is connected to electrodes in the applicator 13 via wires in the cable 12 . The control unit 11 has an input device such as a keypad 10 that allows an operator to input selected values of parameters of the treatment, such as the frequency, pulse duration and intensity of the RF energy. The control unit 11 optionally contains a processor 9 for monitoring and controlling various functions of the device.
[0027] FIG. 2 shows an applicator 13 a that may be used for the applicator 13 in accordance with one embodiment of the invention. The applicator 13 a comprises an electrode 1 from which a plurality of protruding conducting elements 5 extend. Each protruding element 5 (referred to herein as a “pin”) terminates in a tip 7 having a high curvature. The electrical current from the tips is much higher than from flat parts 6 of the electrode. Skin volumes 4 around the tips 7 are therefore heated to a much higher temperature than the surrounding dermis 3 and epidermis 2 , so that the skin volumes 4 may be heated to a coagulation temperature, while the skin temperature in the outside the volumes 4 are not heated to a coagulation temperature. The electrical energy is adjusted to selectively damage skin adjacent to tips so that the treatment of the skin occurs simultaneously at a plurality of discrete volumes 4 . The pulse duration is preferably short enough to prevent significant heat diffusion far from the tips. In order to limit significant heat transfer from the tips, the pulse duration should preferably not exceed 200 ms. The selectivity of the treatment can be improved by electrode cooling of the skin surface. Cooling also causes a more uniform heat distribution at the tips. This can be achieved by circulating a cooling fluid through tubes 8 in the flat regions 6 between the pins 5 . The electrode 1 is contained in a housing 10 connected to the cable 12 . The cable 12 electrically connects the electrode 1 with a terminal of the power source 18 . A second terminal of the power supply 18 may be connected to a ground electrode 20 via a cable 23 (See FIG. 1 ).
[0028] FIG. 3 shows an applicator 13 b that may be used for the applicator 13 in accordance with another embodiment of the invention. The applicator 13 b comprises an electrode 100 consisting of a plurality of conducting pins 101 extending from a conducting plate 102 . The pins 101 are separated by electrical insulating material 105 . The applicator 13 b is used similarly as the applicator 13 a to deliver electrical current to discrete volumes of skin 4 .
[0029] The pins 5 in the applicator 13 a and the pins 101 in the applicator 13 b are provided with blunt tips 7 and 107 , respectively. This prevents the pins 5 and 101 from penetrating into the skin when the electrode 13 a or 13 b is applied t the skin surface. Thus, the applicators 13 a and 13 b provide simultaneous non-invasive coagulation of skin regions 4 .
[0030] FIG. 4 shows an applicator 13 c that may be used for the applicator 13 in accordance with another embodiment of the invention. The applicator 13 c is configured to be used for invasive collagen remodeling. The applicator 13 c includes an electrode 201 having a plurality of protruding conducting pins 205 . The pins 205 have sharp tips 206 that are configured to penetrate through the epidermis 202 into the dermis 203 when pressed on the skin as shown in FIG. 4 . The applicator 13 c is used similarly to the applicators 13 a and 13 b so that the treatment of the skin occurs simultaneously in a plurality of discrete skin volumes 204 . However, unlike the discrete volumes 4 , which are located in the epidermis (see FIGS. 2 and 3 ), the volumes 204 are located below the surface in the dermis 203 ( FIG. 4 ). This reduces skin redness that sometimes occurs when the treated regions are in the epidermis. A maximal current density is created at the tips of the pins 205 . The sides of the protruding elements may be coated with insulating material to avoid skin heating around the pins 205 (not shown).
[0031] The present invention can be combined with other methods of skin treatment including laser treatment. For example non-ablative collagen remodeling by laser radiation may be combined with the invasive RF heating of the skin dermis in accordance with the invention.
[0032] The preferable parameters for non-invasive skin coagulation in accordance with the invention are as follows: [0032] Electrode size above 0.3 cm; [0033] Protruding element at contact with the skin up to 0.5 mm [0034] Protruding element height about 1 mm. [0035] Distance between protruding elements at least twice the element diameter; [0036] Current density: over 1 A/cm.sup.2; [0037] RF current pulse duration: not longer than 0.5 sec; [0038] The optimal parameters for invasive skin coagulation: [0039] Electrode size above 0.3 cm; [0040] Pin diameter at contact with the skin not larger than 0.3 mm [0041] Pin protruding height above 1 mm. [0042] Distance between pins at least 1 mm; [0043] Current density above 0.1 A/cm.sup.2; [0044] RF current pulse duration not longer than 0.5 sec.
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A system and method for simultaneously heating a plurality of discrete skin volumes to a coagulation temperature. The system comprises an applicator containing an electrode having a plurality of spaced apart protruding conducting elements configured to contact the skin surface at a plurality of discrete locations. A controller applies a voltage to the electrode so as to simultaneously heat a plurality of skin volumes to a coagulation temperature when the applicator is applied to the skin surface.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present disclosure generally relates to the fabrication of integrated circuits, and, more particularly, to various methods of forming a semiconductor device with a spacer etch block cap, and the resulting semiconductor device.
[0003] 2. Description of the Related Art
[0004] In modern integrated circuits, such as microprocessors, storage devices and the like, a very large number of circuit elements, especially transistors, are provided and operated on a restricted chip area Immense progress has been made over recent decades with respect to increased performance and reduced feature sizes of circuit elements, such as transistors. However, the ongoing demand for enhanced functionality of electronic devices forces semiconductor manufacturers to steadily reduce the dimensions of the circuit elements and to increase the operating speed of the circuit elements. The continuing scaling of feature sizes, however, involves great efforts in redesigning process techniques and developing new process strategies and tools so as to comply with new design rules. Generally, in complex circuitry including complex logic portions, MOS technology is presently a preferred manufacturing technique in view of device performance and/or power consumption and/or cost efficiency. In integrated circuits fabricated using MOS technology, field effect transistors (FETs), such as planar field effect transistors and/or FinFET transistors, are provided that are typically operated in a switched mode, i.e., these transistor devices exhibit a highly conductive state (on-state) and a high impedance state (off-state). The state of the field effect transistor is controlled by a gate electrode, which controls, upon application of an appropriate control voltage, the conductivity of a channel region formed between a drain region and a source region.
[0005] To improve the operating speed of FETs, and to increase the density of FETs on an integrated circuit device, device designers have greatly reduced the physical size of FETs over the years. More specifically, the channel length of FETs has been significantly decreased, which has resulted in improving the switching speed of FETs. However, decreasing the channel length of a FET also decreases the distance between the source region and the drain region. In general, as a result of the reduced dimensions of the transistor devices, the operating speed of the circuit components has been increased with every new device generation, and the “packing density,” i.e., the number of transistor devices per unit area, in such products has also increased during that time. Such improvements in the performance of transistor devices has reached the point where one limiting factor relating to the operating speed of the final integrated circuit product is no longer the individual transistor element but the electrical performance of the complex wiring system that is formed above the device level that includes the actual semiconductor-based circuit elements.
[0006] Typically, due to the large number of circuit elements and the required complex layout of modern integrated circuits, the electrical connections of the individual circuit elements cannot be established within the same device level on which the circuit elements are manufactured, but require one or more additional metallization layers, which generally include metal-containing lines providing the intra-level electrical connection, and also include a plurality of inter-level connections or vertical connections, which are also referred to as vias. These vertical interconnect structures comprise an appropriate metal and provide the electrical connection of the various stacked metallization layers.
[0007] Furthermore, in order to actually connect the circuit elements formed in the semiconductor material with the metallization layers, an appropriate vertical contact structure is provided, a first lower end of which is connected to a respective contact region of a circuit element, such as a gate electrode and/or the drain and source regions of transistors, and a second end is connected to a respective metal line in the metallization layer by a conductive via. Such vertical contact structures are considered to be “device-level” contacts or simply “contacts” within the industry, as they contact the “device” that is formed in the silicon substrate. The contact structures may comprise contact elements or contact plugs having a generally square-like or round shape that are formed in an interlayer dielectric material, which in turn encloses and passivates the circuit elements. In other applications, the contact structures may be line-type features, e.g., source/drain contact structures.
[0008] In some cases, the second, upper end of the contact structure may be connected to a contact region of another semiconductor-based circuit element, in which case the interconnect structure in the contact level is also referred to as a local interconnect. These local interconnect structures typically connect circuit elements, e.g., transistors, resistors, etc., that are formed on different spaced-apart active regions that are electrically isolated from one another. Such local interconnect structures are generally line-type structures that are formed in the interlayer dielectric material below the metallization system of the product.
[0009] As device dimensions have decreased, e.g., transistors with gate lengths of 50 nm and less, the contact elements in the contact level have to be provided with critical dimensions on the same order of magnitude. The contact elements typically represent plugs, which are formed of an appropriate metal or metal composition, wherein, in sophisticated semiconductor devices, tungsten, in combination with appropriate barrier materials, has proven to be a viable contact metal. When forming tungsten-based contact elements, typically the interlayer dielectric material is formed first and is patterned so as to receive contact openings, which extend through the interlayer dielectric material to the corresponding contact areas of the circuit elements. In particular, in densely packed device regions, the lateral size of the drain and source areas and thus the available area for the contact regions is 100 nm and significantly less, thereby requiring extremely complex lithography and etch techniques in order to form the contact openings with well-defined lateral dimensions and with a high degree of alignment accuracy.
[0010] For this reason, contact technologies have been developed in which contact openings are formed in a self-aligned manner by removing dielectric material, such as silicon dioxide, selectively from the spaces between closely spaced gate electrode structures. That is, after completing the transistor structure, at least the sidewall spacers of the gate electrode structures are used as etch masks for selectively removing the silicon dioxide material in order to expose the contact regions of the transistors, thereby providing self-aligned trenches which are substantially laterally delineated by the spacer structures of the gate electrode structures. Consequently, a corresponding lithography process only needs to define a global contact opening above an active region, wherein the contact trenches then result from the selective etch process using the spacer structures, i.e., the portions exposed by the global contact opening, as an etch mask. Thereafter, an appropriate contact material, such as tungsten and the like, may be filled into the contact trenches.
[0011] However, the aforementioned process of forming self-aligned contacts results in an undesirable loss of at least portions of the spacer materials that protect the conductive gate electrode, as will be explained with reference to FIGS. 1A-1B . FIG. 1A schematically illustrates a cross-sectional view of an integrated circuit product 10 at an advanced manufacturing stage. As illustrated, the product 10 comprises a plurality of illustrative gate structures 11 that are formed above a substrate 12 , such as a silicon substrate. The gate structures 11 are comprised of an illustrative gate insulation layer 13 and an illustrative gate electrode 14 . An illustrative gate cap layer 16 and sidewall spacers 18 encapsulate and protect the gate structures 11 . The gate cap layer 16 and sidewall spacers 18 are typically made of silicon nitride. Also depicted in FIG. 1A are a plurality of raised source/drain regions 20 and a layer of insulating material 22 , e.g., silicon dioxide. FIG. 1B depicts the product 10 after an opening 24 has been formed in the layer of insulating material 22 for a self-aligned contact. Although the contact etch process performed to form the opening 24 is primarily directed at removing the desired portions of the layer of insulating material 22 , portions of the protective gate cap layer 16 and the protective sidewall spacers 18 get consumed during the contact etch process, as simplistically depicted in the dashed regions 26 . Given that the cap layer 16 and the spacers 18 are attacked in the contact etch process, the thickness of these protective materials must be sufficient such that, even after the contact etch process is completed, there remains sufficient material to protect the gate structures 11 . Accordingly, device manufacturers tend to make the cap layers 16 and spacers 18 having an additional thickness that may otherwise not be required but for the consumption of the cap layers 16 and the spacers 18 during the contact etch process. In turn, increasing the thickness of such structures, i.e., increasing the thickness of the gate cap layers 16 , causes other problems, such as increasing the aspect ratio of the contact opening 24 due to the increased height, increasing the initial gate height, which makes the gate etching and spacer etching processes more difficult, etc.
[0012] The present disclosure is directed to various methods of forming a semiconductor device with a spacer etch block cap, and the resulting semiconductor device, that may avoid, or at least reduce, the effects of one or more of the problems identified above.
SUMMARY OF THE INVENTION
[0013] The following presents a simplified summary of the invention in order to provide a basic understanding of some aspects of the invention. This summary is not an exhaustive overview of the invention. It is not intended to identify key or critical elements of the invention or to delineate the scope of the invention. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is discussed later.
[0014] Generally, the present disclosure is directed to various methods of forming a semiconductor device with a protected gate cap layer, and the resulting semiconductor device. One illustrative method disclosed herein includes, among other things, forming a sacrificial gate structure above a semiconductor substrate, forming a sidewall spacer adjacent opposite sides of the sacrificial gate structure, removing the sacrificial gate structure and forming a replacement gate structure in its place, at some point after forming the replacement gate structure, performing an etching process to reduce the height of the spacers so as to thereby define recessed spacers having an upper surface that partially defines a spacer recess, and forming a spacer etch block cap on the upper surface of each recessed spacer structure and within the spacer recess.
[0015] A further illustrative method disclosed herein includes, among other things, forming a sacrificial gate structure above a semiconductor substrate, forming a sidewall spacer adjacent opposite sides of the sacrificial gate structure, forming a first layer of insulating material above the substrate, removing the sacrificial gate structure so as to thereby define a replacement gate cavity, forming a replacement gate structure in the replacement gate cavity, forming a gate cap layer above the replacement gate structure, after forming the gate cap layer, performing an etching process to reduce the height of the spacers so as to thereby define recessed spacers with a spacer recess formed thereabove, wherein the spacer recess is defined by an upper surface of the recessed spacer, the first layer of insulating material and the gate cap layer, and forming a spacer etch block cap on the upper surface of each recessed spacer structure and within the spacer recess.
[0016] One illustrative example of a novel transistor device disclosed herein includes, among other things, a gate structure positioned above a semiconductor substrate, a spacer positioned adjacent opposite sides of the gate structure, a gate cap layer positioned above the gate structure, wherein an upper surface of the gate cap layer is positioned above the upper surface of the spacers, a first layer of insulating material positioned above the substrate, wherein an upper surface of the first layer of insulating material is substantially planar with the upper surface of the gate cap layer and wherein the upper surface of the spacer, the first layer of insulating material and the gate cap layer define a spacer recess above each of the spacers and a spacer etch block cap positioned on the upper surface of each spacer and within the spacer recess.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The disclosure may be understood by reference to the following description taken in conjunction with the accompanying drawings, in which like reference numerals identify like elements, and in which:
[0018] FIGS. 1A-1B schematically illustrate a cross-sectional view of an illustrative prior art integrated circuit product that employs self-aligned contacts; and
[0019] FIGS. 2A-2Q depict various illustrative methods disclosed herein of forming a semiconductor device with a spacer etch block cap, and the resulting semiconductor device.
[0020] While the subject matter disclosed herein is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the description herein of specific embodiments is not intended to limit the invention to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION
[0021] Various illustrative embodiments of the invention are described below. In the interest of clarity, not all features of an actual implementation are described in this specification. It will of course be appreciated that in the development of any such actual embodiment, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure.
[0022] The present subject matter will now be described with reference to the attached figures. Various structures, systems and devices are schematically depicted in the drawings for purposes of explanation only and so as to not obscure the present disclosure with details that are well known to those skilled in the art. Nevertheless, the attached drawings are included to describe and explain illustrative examples of the present disclosure. The words and phrases used herein should be understood and interpreted to have a meaning consistent with the understanding of those words and phrases by those skilled in the relevant art. No special definition of a term or phrase, i.e., a definition that is different from the ordinary and customary meaning as understood by those skilled in the art, is intended to be implied by consistent usage of the term or phrase herein. To the extent that a term or phrase is intended to have a special meaning, i.e., a meaning other than that understood by skilled artisans, such a special definition will be expressly set forth in the specification in a definitional manner that directly and unequivocally provides the special definition for the term or phrase.
[0023] The present disclosure generally relates to various methods of forming a semiconductor device with a spacer etch block cap, and the resulting semiconductor device. Moreover, as will be readily apparent to those skilled in the art upon a complete reading of the present application, the present method is applicable to a variety of devices, including, but not limited to, logic devices, memory devices, etc., and the methods disclosed herein may be employed to form N-type or P-type semiconductor devices. The methods and devices disclosed herein may be employed in manufacturing products using a variety of technologies, e.g., NMOS, PMOS, CMOS, etc., and they may be employed in manufacturing a variety of different devices, e.g., memory devices, logic devices, ASICs, etc. With reference to the attached figures, various illustrative embodiments of the methods and devices disclosed herein will now be described in more detail.
[0024] FIG. 2A schematically illustrates a cross-sectional view of an integrated circuit product 100 at an advanced stage of manufacturing after several process operations were performed. As illustrated, the product 100 comprises a plurality of illustrative, and schematically depicted, sacrificial gate structures 111 that are formed above a substrate 112 . Also depicted are an illustrative etch stop layer 113 , sidewall spacers 118 , raised source/drain regions 120 and a layer of insulating material 122 , e.g., silicon dioxide. The substrate 112 may have a variety of configurations, such as the depicted bulk substrate configuration. The substrate 112 may have an SOI (silicon-on-insulator) configuration wherein the semiconductor devices are formed in the active layer of the SOI substrate. The substrate 112 may be made of silicon or it may be made of materials other than silicon. Thus, the terms “substrate,” “semiconductor substrate” or “semiconducting substrate” should be understood to cover all semiconducting materials and all forms of such materials. The inventions disclosed herein will be disclosed in the context of forming planar transistor devices using a replacement gate process. However, as will be recognized by those skilled in the art after a complete reading of the present application, the inventions disclosed herein may be applied to the formation of planar FET devices as well as 3 D devices, such as FinFET devices. Moreover, the methods disclosed herein are applicable to forming any type of device, e.g., an NFET device, a PFET device, etc.
[0025] With continuing reference to FIG. 2A , the sacrificial gate structures 111 are intended to be representative in nature of any type of sacrificial gate structure that may be employed in manufacturing integrated circuit products using so-called gate-last (replacement gate) manufacturing techniques. In general, the sacrificial gate structures 111 are comprised of a sacrificial gate insulation layer (not separately depicted), such as silicon dioxide, and a sacrificial gate electrode (not separately depicted), such as polysilicon or amorphous silicon. In one illustrative replacement gate manufacturing technique, the layers of material for the sacrificial gate structure including a gate cap layer (not shown) are initially formed/deposited above the substrate 112 and thereafter patterned using traditional masking and etching techniques to thereby define the sacrificial gate structure 111 with a gate cap layer (not shown) positioned above the sacrificial gate structure 111 . Thereafter, the sidewall spacers 118 are formed adjacent the patterned dummy gate structure/cap layer, and the very thin etch stop layer 113 , e.g., silicon nitride, is then conformably deposited across the product 100 . The sacrificial gate structure 111 remains in place (protected by the spacers and the gate cap layer) as many process operations are performed to form the devices, e.g., the formation of the depicted raised, doped source/drain regions 120 , performing an anneal process to repair damage to the substrate 112 caused by the ion implantation processes and to activate the implanted dopant materials.
[0026] With continuing reference to FIG. 2A , the product 100 is depicted after the gate cap layer was removed by performing a chemical mechanical polishing (CMP) process relative to a layer of insulating material 122 so as to expose the dummy gate electrode (polysilicon) of the sacrificial gate structure 111 . FIG. 2A depicts an idealized situation wherein the upper surface of the sacrificial gate structure 111 , the spacers 118 and the layer of insulating material 122 are all substantially planar. In a “real-world” device, there will be a slight difference in height between the gate electrode of the sacrificial gate structure 111 , the spacers 118 and the layer of insulating material 122 due to differences in hardness of the various materials that were removed by the CMP process, and the effect of the polishing slurries on the polished materials. After the sacrificial gate structure 111 is exposed by performing the CMP process, an etching process is performed to insure that the upper surface of the gate electrode of the sacrificial gate structure 111 is clear of the insulating material 122 .
[0027] FIG. 2B depicts a more “real-world” example, wherein there is a difference in height between the gate electrode of the sacrificial gate structure 111 , the spacers 118 and the layer of insulating material 122 due to performing the above-described CMP and etching processes.
[0028] FIG. 2C depicts the product 100 after a gate cap protection layer 126 has been deposited across the product 100 . The gate cap protection layer 126 may be comprised of a variety of different materials, e.g., silicon nitride, that exhibit good etch selectivity relative to the layer of insulating material 122 . The gate cap protection layer 126 may be formed by performing a variety of techniques, e.g., CVD, ALD, etc. The thickness of the gate cap protection layer 126 may vary depending upon the particular application, e.g., 2-8 nm.
[0029] FIG. 2D depicts the product 100 after a layer of insulating material 128 has been deposited across the product 100 . The layer of insulating material 128 may be comprised of a variety of different materials, such as silicon dioxide, etc., and it may be formed by performing a variety of techniques, e.g., CVD, etc. The thickness of the layer of insulating material 128 may vary depending upon the particular application. The layer of insulating material 128 may be comprised of the same or different materials as that of the layer of insulating material 122 .
[0030] FIG. 2E depicts the product 100 after a CMP process was performed to remove portions of the layer of insulating material 128 positioned above the gate cap protection layer 126 . The CMP process may actually stop before it reaches the gate cap protection layer 126 so as not to consume the gate cap protection layer 126 , as would be the case where it is used as a polish-stop layer. In that case, after the CMP process, a brief deglaze process may be performed to insure that the oxide material is removed from above the portion of the gate cap protection layer 126 positioned above the sacrificial gate structure 111 .
[0031] FIG. 2F depicts the product 100 after a chemical mechanical polishing (CMP) process was performed that stopped on the sacrificial gate structure 111 . This process exposes the dummy gate electrode (polysilicon) of the sacrificial gate structure 111 .
[0032] FIG. 2G depicts the product 100 after one or more etching processes were performed to remove the sacrificial gate structure 111 which results in the formation of a replacement gate cavity 114 that is laterally defined by the spacers 118 where the final replacement gate structure for the devices will be formed.
[0033] FIG. 2H depicts the device 100 after illustrative and schematically depicted replacement (final) gate structures 140 were formed in the gate cavities 114 . The gate structure 140 depicted herein is intended to be representative in nature of any type of replacement gate structure that may be employed in manufacturing integrated circuit products. Typically, a pre-clean process will be performed in an attempt to remove all foreign materials from within the gate cavities 114 prior to forming the various layers of material that will become part of the gate structure 140 . The pre-clean process will also remove any residual materials from the layer of insulating material 128 . For example, the gate structure 140 may be formed by sequentially depositing the materials of the gate structure in the gate cavities 114 and above the gate cap protection layer 126 , performing a CMP process to remove excess materials above gate cap protection layer 126 and then performing an etch-back recess etching process such that the upper surface 140 U of the gate structure 140 is at the desired height level. As a specific example, a high-k (k value greater than 10) gate insulation layer (not individually shown), such as hafnium oxide, may be deposited across the product 100 and within the gate cavities 114 on the portions of the substrate 112 (or fin in the case of a FinFET device) exposed by the gate cavities 114 by performing a conformal deposition process, i.e., an ALD or CVD deposition process. If desired, a thin interfacial layer of silicon dioxide (not shown) may be formed prior to the formation the high-k gate insulation layer. Next, at least one work function adjusting metal layer (not separately shown) (e.g., a layer of titanium nitride or TiAlC depending upon the type of transistor device being manufactured) may be deposited on the high-k gate insulation layer and within the gate cavities 114 by performing a conformal ALD or CVD deposition process. Of course, more than one layer of work function metal may be formed in the gate cavities 114 , depending upon the particular device under construction. Then, a bulk conductive material, such as tungsten or aluminum, may be deposited in the gate cavities 114 above the work function adjusting metal layer(s). Thereafter, one or more CMP processes were performed to remove excess portions of the various layers of material positioned above the surface of the gate cap protection layer 126 . Next, a recess etching process was performed so as to remove a desired amount of the materials of the gate structure 140 such that the upper surface 140 U of the gate structures 140 is at the desired height level within the gate cavities 114 . Other possible materials for the gate insulation layer in the gate stack include, but are not limited to, tantalum oxide (Ta 2 O 5 ), hafnium oxide (HfO 2 ), zirconium oxide (ZrO 2 ), titanium oxide (TiO 2 ), aluminum oxide (Al 2 O 3 ), hafnium silicates (HfSiO x ) and the like. Other possible materials for the work function adjusting metal layers include, but are not limited to, titanium (Ti), titanium nitride (TiN), titanium-aluminum (TiAl), titanium-aluminum-carbon (TiALC), aluminum (Al), aluminum nitride (AlN), tantalum (Ta), tantalum nitride (TaN), tantalum carbide (TaC), tantalum carbonitride (TaCN), tantalum silicon nitride (TaSiN), tantalum silicide (TaSi) and the like.
[0034] FIG. 2I depicts the product 100 after a layer of insulating material 142 has been deposited across the product 100 . The layer of insulating material 142 may be comprised of a variety of different materials, such as silicon dioxide, etc., and it may be formed by performing a variety of techniques, e.g., CVD, etc. The thickness of the layer of insulating material 142 may vary depending upon the particular application. The layer of insulating material 142 may be comprised of the same or different materials as that of the layer of insulating material 122 .
[0035] FIG. 2J depicts the product 100 after a CMP process was performed to remove portions of the layer of insulating material 142 positioned above the gate cap protection layer 126 . This results in portions of the layer of insulating material 142 becoming a gate cap layer 142 A positioned in the gate cavities 114 above the gate structures 140 .
[0036] FIG. 2K depicts the product 100 after a timed recess etching process was performed to selectively remove portions of the spacers 118 , the etch stop layer 113 and any remaining portions of the gate cap protection layer 126 selectively relative to the surrounding materials. This process operation results in the formation of a plurality of recessed spacers 118 R with a spacer recess 118 X formed above the recessed spacers 118 R. The spacer recess 118 X is defined by an upper surface 118 U of the recessed spacer 118 R, the layer of insulating material 122 and the gate cap layer 142 A. The depth of the spacer recess 118 X may vary depending upon the particular application. In one illustrative embodiment, the spacer recess 118 X may have a depth on the order of about 5-20 nm relative to the upper surface of the layer of insulating material 122 . In one illustrative embodiment, the etching process performed to form the spacer recesses 118 X may be an anisotropic etching process.
[0037] FIG. 2L depicts the product 100 after a spacer etch block cap 150 was formed in each spacer recess 118 X. The spacer etch block caps 150 were formed by depositing a layer of etch block material, e.g., a high-k insulating material (which for purposes of the inventions disclosed herein will be understood to have a k-value greater than 10), such as hafnium oxide, aluminum oxide, or a carbon-containing material, such as SiCBN, SiC, etc., so as to overfill the spacer recesses 118 X, and thereafter performing a CMP process to remove the excess etch block material using the layer of insulating material 122 as a polish-stop layer. Note that at this point in the process flow, the upper surfaces of the spacer etch block cap 150 , the layer of insulating material 122 and the gate cap layer 142 A are all substantially planar.
[0038] FIG. 2M depicts the product 100 after a layer of insulating material 152 was deposited across the product 100 . The layer of insulating material 152 may be comprised of a variety of different materials, such as silicon dioxide, a low-k (k value less than 3.3) material, etc., and it may be formed by performing a variety of techniques, e.g., CVD, etc. The thickness of the layer of insulating material 152 may vary depending upon the particular application.
[0039] FIG. 2N depicts the product 100 after one or more anisotropic etching processes were performed on the product 100 through a patterned etch mask (not shown), such as a patterned layer of photoresist material, to remove portions of the layer of insulating material 152 and substantially all of the layer of insulating material 122 exposed by the patterned etch mask layer to thereby define a plurality of self-aligned contact openings 154 . In the depicted example, the self-aligned contact openings 154 are depicted as being precisely aligned relative to the gate structures 140 . However, in a real-world device, the self-aligned contact openings 154 may be somewhat misaligned relative to the gate structures 140 . During the formation of the self-aligned contact openings 154 , the spacer etch block caps 150 remain in position to protect the gate structure 140 . As depicted, formation of the contact openings 154 will likely expose at least a portion of the spacer etch block caps 150 . Some of the spacer etch block caps 150 and the etch stop layer 113 may be consumed during the formation of the contact openings 154 , although such a situation is not depicted in FIG. 2N .
[0040] FIG. 2O depicts the device 100 after a very brief “punch through” etching process is performed to remove at least portions of the etch stop layer 113 (as well as any other residual materials) so as to thereby expose the source/drain regions 120 . In the depicted example, the etching process removes substantially all of the etch stop layer 113 . In some cases, portions of the etch stop layer 113 may remain positioned adjacent the recessed spacers 118 R.
[0041] FIG. 2P depicts the product 100 after optional metal silicide regions 158 have been formed in the source/drain regions 120 of the devices through the contact openings 154 in the layer of insulating material 152 . The metal silicide regions 158 may be formed by performing traditional silicide formation techniques.
[0042] FIG. 2Q depicts the product 100 after conductive, self-aligned contact structures 160 have been formed in the self-aligned contact openings 154 such that they are conductively coupled to the source/drain regions 120 . Note that the self-aligned contact structures 160 abut and engage the spacer etch block caps 150 . The self-aligned contact structures 160 are intended to be schematic and representative in nature, as they may be formed using any of a variety of different conductive materials and by performing traditional manufacturing operations. The self-aligned contact structures 160 may also contain one or more barrier layers (not depicted). In one illustrative example, the self-aligned contact structures 160 may be formed by depositing a liner, e.g., a titanium nitride liner, followed by overfilling the self-aligned contact openings 154 with a conductive material, such as tungsten. Thereafter, a CMP process may be performed to planarize the upper surface of the layer of insulating material 152 which results in the removal of excess portions of the liner and the tungsten positioned above the layer of insulating material 152 outside of the self-aligned contact openings 154 and the formation of the self-aligned contact structures 160 .
[0043] The particular embodiments disclosed above are illustrative only, as the invention may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. For example, the process steps set forth above may be performed in a different order. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the invention. Note that the use of terms, such as “first,” “second,” “third” or “fourth” to describe various processes or structures in this specification and in the attached claims is only used as a shorthand reference to such steps/structures and does not necessarily imply that such steps/structures are performed/formed in that ordered sequence. Of course, depending upon the exact claim language, an ordered sequence of such processes may or may not be required. Accordingly, the protection sought herein is as set forth in the claims below.
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One illustrative method disclosed herein includes, among other things, forming a sacrificial gate structure above a semiconductor substrate, forming a sidewall spacer adjacent opposite sides of the sacrificial gate structure, removing the sacrificial gate structure and forming a replacement gate structure in its place, at some point after forming the replacement gate structure, performing an etching process to reduce the height of the spacers so as to thereby define recessed spacers having an upper surface that partially defines a spacer recess, and forming a spacer etch block cap on the upper surface of each recessed spacer structure and within the spacer recess.
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RELATED APPLICATIONS
The application is related to U.S. Provisional Patent Application, Ser. No. 60/355,733, filed on Feb. 7, 2002, incorporated herein by reference and to which priority is claimed pursuant to 35 USC 119.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to the field of nitroxide mediated free radical polymerization of vaporized vinyl monomers, including acrylic acid (AAc), styrene (St), N-2-(hydroxypropyl)methacrylamide (HPMA) and N-isopropyl acrylamide (NIPAAm), on silicon wafers.
2. Description of the Prior Art
Fabrication of polymer ultrathin films with controllable surface properties is critical in many important industrial applications and academic research. As device sizes continue to shrink, the use of surface-initiated polymerization, where polymer films were directly polymerized from surface premodified initiator layers, has become increasingly important over conventional coating methods. The polymer films fabricated via the surface-initiated polymerization are end-grafted monolayers with superior chemical/mechanical stability and controllable grafting thickness and density. Typically, polymerization schemes were directly adapted from the already existed chemical synthetic schemes for their counterpart polymeric materials. However, in a surface-initiated polymerization scheme, the initiators are crowded on a two-dimensional surface and the polymerization only take place at interfaces. This inherent nature has often raised difficulty in synthesizing high molecular weight polymer products in that the effective monomer to initiator ratio near surface is lower, while the premature termination caused by impurities or side reactions in solution are more dominant than the typical polymerization where both monomers and initiators are evenly dispersed in the media. Previously, empirical methods such as adding excess initiator molecules in solution phase were proposed to improve the yield.
The prior art has described the synthesis of polymer brushes by living free radical polymerization using another similar alkoxylamine initiator, but it was performed in liquid phase. The reaction performed in liquid is quite different from that in gas phase. There have been some limited work on the synthesis of polymer (polypeptide) brushes by living polymerization using quite different initiators. Besides they used condensation polymerization techniques instead of addition polymerization in our system.
As with preparation of self-assembled monolayers (SAMs), polymer brushes are typically formed by first depositing initiating groups on a substrate surface that covalently bind thereto. Then, macromolecular chains are grown from the initiating groups using monomers that are typically similar to those traditionally used in microlithography, e.g., t-butyl acrylate. The covalent bonding of the macromolecular chains to the substrate surface opens up a number of possibilities that are not available with traditional spin-cast films. These advantages permit the use of these films in technological applications that include specialty photoresists, sensors and microfluidic networks.
A number of different approaches to synthesis of patterned polymer brushes have been described. For example, some have reported the patterning of surface bound initiators by either photoablation or photoinitiation, followed by polymerization to give discrete areas of polymer brushes, while others have detailed the growth of patterned polymer films using layer by layer techniques. In addition, a number of groups have also reported the elaboration of microcontact printed thiol monolayers to provide patterned polymer brushes.
In the past, studies have been done on graft polymerization for surface modification, but the main difficulty was the poor controlling of composition, architecture and function of the polymer layer. The appearance of living polymerization provided the chance of changing this situation. In the recent years, efforts have been made by the combination of graft polymerization and living polymerization, some have succeeded. Usually they were not highly efficient in initiating graft polymerization and applicable to various monomer systems. Most importantly, they were not good in patterning the polymer layer due to the limitation of solvent in most systems.
Ever since the nitroxide-mediated radical polymerization was proposed by M. K. Georges et al in 1994, it has been widely investigated in many polymeric systems. It is a very attractive approach to synthesize not only living homopolymers but also block-copolymers, as a result of its living characteristic. More recently, this approach has also been used to synthesize polymer from an immobilized TEMPO initiator layers at surfaces, thus creating an end-grafted polymer thin film layer as shown by Husseman, et al in 1999.
BRIEF SUMMARY OF THE INVENTION
In the illustrated embodiment of the invention vaporized acrylic monomers are used, as opposed to the solvated monomers, as the source for synthesizing end-grafted block copolymer ultrathin films on solid substrates. Conceptually, polymerization at vapor provides a means to reduce the consumption of solvents, to eliminate time to purge off O 2 , to shorten the reaction time, and to more easily pattern the surfaces.
The illustrated embodiment is directed to a fabrication method for organic ultrathin films (1˜100 nm) by utilizing vapor deposition polymerization in vacuum. A variety of polymer brushes grafted on silicon oxide surfaces are fabricated through the living polymerization of vaporized vinyl monomers from the surface initiator layer. In particular, a derivative of 2,2,6,6-tetramethyl piperidinyloxy (TEMPO) based alkoxylamine containing trimethoxysilyl is pre-immobilized on the silicon (100) wafer with the TEMPO group at the free end, which is applied for initiating the growth of the grafted polymer layers from the surface via living free radical polymerization. This polymerization is performed in vapor phase instead of the conventional solution phase. To monitor the chemical structures, growth of films, and the surface energy, Fourier transform infrared spectrum (FTIR), ellipsometry and contact angle goniometry are employed. It is found that a thickness up to sub-micron is attainable within less than 2 hours. A nearly linear relationship between the polymer film thickness and the reaction time enables an easy and exact control of the resulting polymer thickness. In addition, the polymers with various chemical functional groups, including phenyl, carboxyl, amide, and hydroxyl, are successfully fabricated followed by the same protocol. The fabricated Poly N-isopropyl acrylamide (PNIPAAm) film also exhibits the unique reversible thermo-sensitive feature of a homopolymer in aqueous system. Corresponding to the decrease of temperature across the lower critical solution temperature (LCST) of PNIPAAm, the thickness of PNIPAAm layer extended more than 50% due to the phase transition. Besides, the living character of this polymerization process allows the fabrication of not only di-block copolymers, but also tri-block copolymers such as PAAc-b-PSt-b-PHPMA, demonstrating the feasibility of exact control of surface polymer composition and morphology at nanoscale.
The invention relates generally to:
1. a fabrication method for creating polymer thin films with controlled properties; 2. a fabrication method utilizing free radical polymerization of vaporized vinyl monomers in vacuum to synthesize wide variety of polymer thin films; 3. a fabrication method combined with photolithography for creating surface patterns; 4. a composition of matter for polymeric materials including polystyrene (PS), polymers with functional groups such as hydroxy, carboxy, and amide, and/or block copolymers composed of more than two of the above mentioned polymers; 5. a thin film with a thickness controlled from 1 nm up to submicron sizes; and 6. a method for creating “smart surfaces”, where surface properties can be regulated through the environment stimulants and become fully reversible/recyclable as a product.
The invention relates to the synthesis of graft functional polymers and block copolymers on solid surface in vapor phase. Using the specially synthesized alkoxylamine initiator covalently immobilized on silicon wafer to initiate living free radical polymerization in vapor phase, functional polymers or block copolymers layers are fabricated. The purpose or the invention is to synthesize graft polymers with well-defined composition, architecture and function for surface modification. The obtained surface layer not only contains the designed surface properties such as hydrophobicity or hydrophilicity and functional groups, but also has precise structure or even pattern. It is applicable to most vinyl monomers. It is a kind of nitroxide-mediated living free radical polymerization, and based on a vapor deposition technique, it is performed in vapor phase instead of conventional liquid phase.
The method of the invention is applicable to most of the vinyl monomers, which offers more opportunity in fabricating polymer layers with various functions. The stimuli-responsive polymer layers can be obtained easily. The thickness of the fabricated polymer is well controlled from a few nanometers up to submicron thicknesses. Block copolymers are easily produced. Finally, the solvent free process due to the vapor phase polymerization greatly favors the surface patterning since it avoids the adverse effect on photomasks.
One of the promising fields for the present invention is in the field of biochips. The capability of precisely controlling composition and architecture of surface polymer layers together with the fine patterning techniques can produce chips with well-patterned biomolecules for diagnosis and treatment. It is advantageous also for patterning on silicon and metals with nanometer thickness which opens a large market in microelectronics. Besides, the invention can be used in many other areas such as microfluidics, separation, optics, and the like.
One advantage of the invention compared to the prior art methods is that the invention produces a product which is a much more densely packed, self-regulating (sensing), and fully recyclable. The resulting polymer thin films can be widely used for biochips, coatings on biomedical devices for improving biocompatibility, for coating a surface for antifouling, and anti-corrosion.
While the apparatus and method has or will be described for the sake of grammatical fluidity with functional explanations, it is to be expressly understood that the claims, unless expressly formulated under 35 USC 112, are not to be construed as necessarily limited in any way by the construction of “means” or “steps” limitations, but are to be accorded the full scope of the meaning and equivalents of the definition provided by the claims under the judicial doctrine of equivalents, and in the case where the claims are expressly formulated under 35 USC 112 are to be accorded full statutory equivalents under 35 USC 112. The invention can be better visualized by turning now to the following drawings wherein like elements are referenced by like numerals.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph showing the FTIR spectra for silicon wafers grafted with line (A) corresponding to PAAc (30 nm, reaction time: 18 min), line (B) corresponding to PSt (150 nm, 2 h), line (C) corresponding to PHPMA (12 nm, 2 h), and line (D) corresponding to PNIPAAm (29 nm, 5 h).
FIG. 2 is a graph showing the dependence of the thickness of PAAc grafted on silicon wafer on polymerization time
FIG. 3 is a graph of the FTIR spectra of the grafted thin film samples after sequential polymerizations. Line (A) shows the spectrum after first polymerization from the TEMPO initiator: PAAc homopolymer (30 nm, 18 min), and Line (B) shows the spectrum after second polymerization from the PAAc film: Di-block PAA (30 nm, 18 min)-b-PSt (25 nm, 1 h), and line (C) shows the spectrum after third polymerization from the diblock film: Tri-block PAA(30 nm, 18 min )-b-PSt (25 nm, 1 h)-b-PHPMA (10 nm, 3 h).
FIG. 4 is a graph which shows the change of the thickness and refractive index of a grafted PNIPAAm film with time in water when the temperature decreases from 50° C. to 22° C. The measured thickness of the PNIPAAm film is 65 nm in air.
FIG. 5 is a table summarizing the vaporized acrylic monomers used in the illustrated embodiment.
FIG. 6 is a table summarizing the fabrication of end-grafted homopolymer thin films using nitroxide mediated radical polymerization in the illustrated embodiment.
FIG. 7 is a table summarizing the fabrication of block copolymer thin films using nitroxide mediated radical polymerization in the illustrated embodiment.
FIG. 8 is a simplified diagram showing a device used for vapor polymerization.
FIG. 9 is a graph showing contact angle as a function of polymerization time demonstrating the heating effect of the TEMPO modified silicon substrate for polymerization of PAA.
FIG. 10 illustrates the ellipsometric thickness of the film as a function of polymerization time of PAA.
The invention and its various embodiments can now be better understood by turning to the following detailed description of the preferred embodiments which are presented as illustrated examples of the invention defined in the claims. It is expressly understood that the invention as defined by the claims may be broader than the illustrated embodiments described below.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the illustrated embodiment a vapor phase reaction scheme is used to synthesize grafted polymer thin films. Inspired by the success of gas phase reactions, such as chemical vapor deposition (CVD) evaporation, and sputtering, in semiconductor and metallic thin film fabrication, a vapor phase scheme, if chemically feasible, has many advantages over the conventional solution phase reactions in synthesizing high molecular weight thin film materials.
First, the vacuum environment can greatly eliminate impurities and solvent molecules, thus prolonging the mean free path of vaporized monomers reaching down the initiator-modified surfaces.
Second, a more efficient surface reaction can be facilitated in that vaporized monomers possess higher thermal energy and can be directional if desired.
Third, the reaction parameters such as the evaporating temperature of monomers, the substrate temperature, degree of vacuum, concentration of monomers, type of monomers, etc, can be adjusted independently and quickly in a vapor phase reaction. Potentially, the vapor phase reaction could be a more versatile method in fabricating polymer films with patterns and multiple compositions in three dimensions. This argument has been experimentally confirmed in the case of ring-opening polymerization of N-carboxy anhydrides (NCAs) of amino acids from the surface initiators. When the parameters were optimized, the thickness of the grafted polypeptide film synthesized via the so-called “surface initiated vapor deposition-polymerization” (SI-VDP) is 10-fold higher than those were produced in the solution phase polymerization.
To demonstrate the feasibility of SI-VDP of monomers which were typically in solvated or liquid forms previously, we have chosen nitroxide-mediated free radical polymerization of vinyl monomers as the model system as diagrammatically summarized in FIG. 5 . This reaction scheme has been demonstrated as a living (or “controlled”) polymerization in solution phase for some industrially important monomers such as styrene, and its surface-initiated protocol has been successfully developed previously. Hence, the selection allows us to investigate both synthetic capability as well as the “controlled” feature of this important polymer category in an SI-VDP setup. To do so, various vaporized vinyl monomers, including styrene, acrylate and acrylamide, were used to synthesize both homo- and block co-polymer brushes as described below.
The initiator, 1-(4-oxa-2′-phenyl-12′-trimethoxysilyl dodecyloxy)-2,2,6,6-tetramethyl-piperidine (I) (TEMPO), was synthesized and pre-deposited on a silicon (100) native oxide surface via the silanol condensation reaction of trimethoxysilane head groups. The modified silicon substrate was placed in a vacuum chamber containing a small amount of monomers. At least 8 mm displacement between the substrate and monomer source was placed to ensure no direct contact. The chamber was evacuated under 10 −3 Torr and sealed, and the temperature was elevated at 125° C. to activate TEMPO initiators, and to vaporize monomers. After the reactions, the samples were cleaned thoroughly to remove loosely-bound physisorbed materials followed by conventional cleaning procedures.
Poly(acrylic acid) (PAAc) brushes were first fabricated on silicon wafers by the SI-VDP of vaporized acrylic acid (AAc) monomers. The successful fabrication of the film was confirmed by its transmission Fourier transform infrared spectrum (t-FTIR), which has the identical characteristic peaks such as the strong absorbance at 1720 cm −1 attributed to carboxylic side chains to the standard PAAc material. Line (A) in FIG. 1 shows the t-FTIR spectrum of one particular grafted PAAc sample synthesized by the SI-VDP for 18 min. The corresponding film thickness of the grafted sample measured by Ellipsometer is 30 nm.
Other monomers, including styrene (St), N-(2-hydroxypropyl)methacrylamide (HPMA) and, N-isopropyl acrylamide (NIPAAm), were also applied in the SI-VDP scheme. Lines (B), (C), and (D) in FIG. 1 are the spectra of the corresponding polymer films respectively. The characteristic peaks from each spectrum match the corresponding polymer standard, thus confirming the feasibility of applying these vaporized monomers in a TEMPO-initiated radical polymerization. Simultaneously, X-ray photoelectron spectroscopy (XPS) was employed to examine the surface composition of grafted PAAc, PSt, and PHPMA films, and the surface elemental analysis based on the individual XPS scans is summarized in Table 1. The experimental compositional ratios are in good agreement with the theoretical stoichiometric ratios of each polymer species, further confirming the results from FTIR.
TABLE 1
XPS data of polymers grafted on silicon wafer
Surface composition
Reac-
Ellipsometric
N C(1s) :N N(1s) :N O(1s) : N Si(2p)
tion
thickness
XPS
Theoretical value of pure
Sample
time
(nm)
experimental
polymer sample
PAAc
0.5 h
61
61:0:39:0
60:0:40:0
PSt
1 h
84
74:0:18:8
100:0:0:0
PHPMA
5 h
26
67:10:23:0
70:10:20:0
* The presence of O(1s) is attributed by the silicon oxide substrate (SiO x ), indicating the presence of defects in this particular sample.
We also performed the surface polymerization of abovementioned monomers in solution phase in order to compare the results with those from the SI-VDP schemes. By adjusting the reaction parameters appropriately, we were able to fabricate grafted PMc, PSt and PHPMA thin films in both vapor and solution phase with comparable results. However, to date we have not been able to produce grafted PNIPAAm films in any circumstances. For example, we have tried the polymerization in different solutions including water, alcohol, toluene, and dioxane, but none of them generates surface-bound PNIPAAm brushes. This suggests that the SI-VDP technique does offer unique advantages for the polymer systems that are difficult or impossible to obtain in conventional solution phase.
With the successful fabrication of grafted PNIPAAm via the SI-VDP, for the first time, we are able to study the temperature response of this thermal-sensitive polymer in an end-grafting state. PNIPAAm is known to reversibly expand when temperature is below its lower critical solution temperature (LCST) in the aqueous solution. Therefore, a film of grafted PNIPAAm is anticipated to change its dielectric properties (such as film thickness and refractive index) with temperature. Indeed, using ellipsometry to measure the thickness of the PNIPAAm film in situ, we found that the solvated PNIPAAm film with an original thickness of 120 nm (>32° C.) can expand over 200 nm (<32° C.) below its LCST point as illustrated in FIG. 2 .
The kinetic plot of ellipsometric film thickness of the resulting grafted PAAc film versus polymerization time, as shown in FIG. 2 , demonstrates that the SI-VDP via nitroxide-mediated polymerization scheme is effective in synthesizing PAAc films. Within a 2 h reaction, a film of nearly 200 nm thickness was obtained. While the monomer concentration in solution polymerization decreases as the reaction progresses, in a SI-VDP setup, the vaporized monomer concentration remains constant throughout the reaction. According to Rault's law, as far as there is condensed monomer in excess, the monomer is saturated at vapor phase in equilibrium state. Accordingly, the average chain molecular weight of the film is proportional to the rate of polymerization.
As shown in FIG. 2 , within 2 h, the polymer thickness and reaction time remains linearly proportional, confirming our hypothetical model. The linear relationship allows one to control the resulting thicknesses by controlling the reaction time. FIG. 10 illustrates the ellipsometric thickness of the film as a function of polymerization time of PAA.
Although we have not fully optimized the reaction conditions for each polymer system, the current results show that the grafting efficiency is highly dependent upon the side chain groups. For example, the grafted PAAc or PSt films required less time than the grafted PHPMA or PNIPAAm films to reach the same thickness level, i.e. 150 nm thickness of PAAc or PSt film was generated in 2 h.
One unique feature of nitroxide-mediated free radical polymerization is the presence of dormant alkoxyamine groups at the chain ends of the formed polymers (mainly styrene-based polymers), which is capable to re-initiate polymerization to create a second block of polymer when the reaction conditions are resumed.
Because such a “living” characteristic is important toward controlling surface composition and morphology at nanoscale, it would be of great interest if the SI-VDP protocol also remains “renewable”. In our case, we conducted SI-VDP for multiple cycles to demonstrate its renewability. By two sequential polymerization, the amphiphilic monolayer composed of grafted diblock copolymers of PAAc (the 1 st layer)-b-PSt (the 2 nd layer), or PSt (the 1 st layer)-b-PAAc (the 2 nd layer) were fabricated. More strikingly, by three sequential polymerization, the grafted triblock copolymer of PAAc (30 nm, the 1 st layer), PSt (25 nm, the 2 nd layer) and PHPMA (10 nm, the 3 rd layer) was demonstrated. The t-FTIR spectra in FIG. 3 show the sequential formation of the triblock copolymer. The water contact angles of the surfaces after each polymerization cycle, as indicated in Table 2, are the complementary evidence of successful grafting of each layer: The grafting of PAAc or PHPMA as the outmost layers led to a hydrophilic surface, while PSt led to a hydrophobic one. The creation of a hydrophilic-hydrophobic-hydrophilic alternating polymer thin film clearly confirms the renewal capability of TEMPO-initiated polymerization at vapor phase.
TABLE 2
Advanced water contact angle after sequential surface reactions
Clean Si
TEMPO
Treatment
wafer
Initiator
PAAc a
Diblock b
Triblock c
Contact
10 ± 2
60 ± 2
40 ± 2.5
90 ± 2.5
49 ± 2.5
angle (°)
a˜c Vapor polymerization for the synthesis of a PAAc (30 nm). b PAAc (30 nm)-b-PSt (25 nm). c PAAc (30 nm)-b-PSt (25 nm)-b-PHPMA (10 nm).
In summary, we have successfully demonstrated the applicability of nitroxide mediated polymerization of vaporized vinyl monomers. Through this SI-VDP process, grafted PAAc thin films with thicknesses from few nanometers to submicrons were fabricated within hours. Interestingly, its linear relationship between thickness and reaction time allows one to further predict and control the resulting film thickness.
Furthermore, other thin films of homopolymers (PSt, PHPMA, and PNIPAAm) as diagrammatically depicted in FIG. 6 and block copolymers, including the triblock copolymer of PAAc-b-PSt-b-PHPMA, as diagrammatically depicted in FIG. 7 were also obtained successfully.
Finally, the combination of solvent-free process and surface-initiated polymerization does provide not only an environmentally cleaner and more efficient technique for fabricating polymeric thin films than the existing solution polymerization, but also a more flexible protocol for surface patterning. In analogy to the vapor phase process in semiconductor manufacturing, the conventional photolithographic techniques are completely applicable for this fabrication process for organic thin film synthesis, as it avoids the adverse effect on photomasking that usually arises from the interference of solvents.
AN EXAMPLE
An experimental example of one embodiment will make the invention clear. A silicon wafer was cleaned with H 2 O 2 /H 2 SO 4 (3/7, v/v) and immersed in solution of initiator in anhydrous toluene for 2 h at room temperature. The TEMPO initiator was tethered on the silicon oxide surface 10 through the silanol condensation reaction and confirmed by ellipsometry and contact angle measurements. After extensive washing and drying, the initiator immobilized silicon wafer 12 mounted on a metal plate 22 was placed into a reaction chamber 14 containing small amount of monomers 16 as shown diagrammatically in FIG. 8 . The temperature of plate 22 and hence wafer 12 was monitored by a thermocouple 18 and a heater coil 20 was thermally coupled to plate 22 to precisely control the temperature of wafer 12 . Oxygen in that reaction chamber 14 was removed completely by repeating at least three cycles of evacuating and then purging with nitrogen. Finally the reaction chamber 14 was evacuated to about 1×10 −3 Torr, sealed and transferred to an oven or oil bath at 125° C. for a designed period. After the reaction, the silicon wafer 12 was cleaned thoroughly with appropriate solvents to remove non-covalently bound species. FIG. 9 illustrates the importance of temperature control of wafer 12 where full coverage of a PAA film can be synthesized in just 5 minutes if wafer 12 is maintained in the range of 90 to 100° C. as opposed to more than 40 minutes if there is no wafer heating.
The surface-grafted PNIPAAm (65 nm in air) was put into a liquid cell full of water at high temperature (higher than its LCST). During the decrease of temperature with time, the change of PNIPAAm thickness and refractive index in water was measured by ellipsometry as illustrated in FIG. 4 .
Many alterations and modifications may be made by those having ordinary skill in the art without departing from the spirit and scope of the invention. Therefore, it must be understood that the illustrated embodiment has been set forth only for the purposes of example and that it should not be taken as limiting the invention as defined by the following claims. For example, notwithstanding the fact that the elements of a claim are set forth below in a certain combination, it must be expressly understood that the invention includes other combinations of fewer, more or different elements, which are disclosed in above even when not initially claimed in such combinations.
The words used in this specification to describe the invention and its various embodiments are to be understood not only in the sense of their commonly defined meanings, but to include by special definition in this specification structure, material or acts beyond the scope of the commonly defined meanings. Thus if an element can be understood in the context of this specification as including more than one meaning, then its use in a claim must be understood as being generic to all possible meanings supported by the specification and by the word itself.
The definitions of the words or elements of the following claims are, therefore, defined in this specification to include not only the combination of elements which are literally set forth, but all equivalent structure, material or acts for performing substantially the same function in substantially the same way to obtain substantially the same result. In this sense it is therefore contemplated that an equivalent substitution of two or more elements may be made for any one of the elements in the claims below or that a single element may be substituted for two or more elements in a claim. Although elements may be described above as acting in certain combinations and even initially claimed as such, it is to be expressly understood that one or more elements from a claimed combination can in some cases be excised from the combination and that the claimed combination may be directed to a subcombination or variation of a subcombination.
Insubstantial changes from the claimed subject matter as viewed by a person with ordinary skill in the art, now known or later devised, are expressly contemplated as being equivalently within the scope of the claims. Therefore, obvious substitutions now or later known to one with ordinary skill in the art are defined to be within the scope of the defined elements.
The claims are thus to be understood to include what is specifically illustrated and described above, what is conceptionally equivalent, what can be obviously substituted and also what essentially incorporates the essential idea of the invention.
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Nitroxide mediated free radical polymerization of vaporized vinyl monomers, including acrylic acid (AAc), styrene (St), N-2-(hydroxypropyl)methacrylamide (HPMA) and N-isopropyl acrylamide (NIPAAm), on silicon wafers is demonstrated. FTIR, ellipsometry and contact angle goniometry were used to characterize the chemical structures, thickness and hydrophilicity of the films. The growth of film is linearly proportional to its reaction time, leading to the easy and exact control of polymer film thickness from nanometers to submicrons. The capability of polymerizing various monomers allows us to fabricate various functional polymer brushes. The reversible thermo-responsiveness of a 200 nm thick grafted poly(NIPAAm) film in aqueous solution is demonstrated with over 50% change in thickness at its lower critical solution temperature. A tri-block copolymer of poly(AAc)-b-polySt-b-poly(HPMA) is successfully synthesized, proving the renewability of TEMPO-mediated polymerization at vapor phase. Surface polymer composition and morphology is thus controlled at nanoscale by utilizing vapor phase surface-initiated controlled polymerization.
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RELATED APPLICATIONS
Not applicable
FIELD OF INVENTION
The present invention relates to digestion of wood chips in a digester employing alkaline liquor for the production of paper pulp.
BACKGROUND OF INVENTION
In the papermaking industry, wood logs are converted into chips, which are subsequently treated in a digester system to separate the cellulose fibers and to remove desired amounts of lignin, etc., which binds the fibers together in the natural state of wood, for the production of paper pulp. Digestion of wood chips employing an alkaline liquor is a common practice in the industry. In this process, commonly wood chips and an alkaline digesting liquor, sometimes premixed, are introduced to a top inlet zone of a continuous digestion vessel (a digester). In the digestion process, the chips and liquor move generally, but not always, together downward through the digester, the digestion reaching generally optimal completion when the mass reaches the bottom portion of the digester. A typical digester is divided into various zones such as the inlet zone, an upper digestion zone within which, among other things, the chip/liquor mass is heated toward a full cook temperature, a full cook zone within which the mass is subjected to a full cook temperature for a selected period of time, an extraction zone within which digestion spent liquor (black liquor at this point) is withdrawn from the digester, a wash zone in which the mass is washed with process liquids to wash the dissolved solids in the black liquor from the mass, and a withdrawal zone in which the mass of (partially) washed pulp is withdrawn from the digester and passed to further treatment apparatus, such as pulp washers.
Scaling occurs on surfaces of the equipment in an alkaline pulping system and results in loss in productivity and higher operating costs. Severe scaling in a continuous digester system often leads to loss of production of up to several days a year for scale removal by acid cleaning or high-pressure hydro blasting. Currently there are no known cost-effective process modifications to prevent scaling from forming, and many mills rely on the use of a class of expensive chemicals, known as “antiscalants” in the art, as pulping additives to suppress scaling. Even with the antiscalants, costly periodic cleaning of heaters or other digester equipment is often required.
Calcium carbonate has been shown to be a key component of scale formed on surfaces of alkaline pulping equipment such as digester cooking heaters and digester screens. In addition, wood generally is the single largest source of calcium present in cooking liquor. The solubility of calcium salts in alkaline pulping liquor has been found first increases and then decreases with increasing cooking temperature and/or cooking time. When the amount of calcium in the cooking liquor exceeds its solubility, calcium precipitates as calcium carbonate and, along with lignin and other deposits, forms scale on the surface of heater, screens and digester shell wall. Thus, under typical alkaline pulping conditions, the amount of dissolved calcium in the cooking liquor increases as cooking proceeds, goes through a maximum near when the maximum cooking temperature is reached, and decreases rapidly afterward as a result of calcium carbonate precipitation onto equipment surfaces (scaling) and surfaces of chips/fibers.
Scaling tendency of calcium in cooking liquor has been shown to decrease dramatically after the liquor has been heated at or near typical full cooking temperatures. This action is, at times, referred to in the art as calcium deactivation by heat treatment, and has been practiced in some digesters. An exemplary application of this calcium deactivation, as described in European Patent Application EP 0313730 A1, comprises of heating cooking liquor high in calcium at or near full cooking temperature, holding it at this temperature in a vessel for a period of time, typically longer than ten minutes, and returning the heat treated liquor, with “deactivated” calcium, to the digester system. Because scale forms on the surfaces of this “sacrificial” vessel, generally at least two vessels are needed in order to maintain continuous operation of calcium deactivation, with at least one vessel being online and one vessel being cleaned of scales. This technology is probably effective, but requires addition capital and operating costs, and therefore is not widely practiced in the industry.
Cleaning accumulated scale from a digester requires taking the digester offline and removal of the scale, commonly by chemical dissolution of the scale and/or pressure cleaning with a liquid. This cleaning consumes several days of downtime of the digester in addition to the labor required to perform the cleaning, both of which are very costly. As a consequence of such cost, cleaning of digesters is commonly conducted no more frequently than annually. The gradual accumulation of scale within the digester over the period of a year results in ever increasing loss of efficiency as more and more scale develops. It is therefore most desirable that a method be provided for reducing or substantially eliminating the accumulation of scale within a digester.
SUMMARY OF PRESENT INVENTION
One aspect of the present invention relates to an improved method of operating a digester for converting wood chips into papermaking pulp employing an alkaline cooking liquor where the digester includes an upright generally cylindrical vessel having a top end and a bottom end in which the deposition of calcium carbonate scale onto surfaces of a digester and/or its ancillary equipment is reduced. In the first step of the improved method a first quantity of cooking liquor having a first concentration of dissolved calcium therein is extracted from a first location intermediate the top and bottom ends of the vessel. In the second step, a second quantity of cooking liquor having a second concentration of dissolved calcium therein that is less than said first concentration of dissolved calcium is extracted from the vessel at a second location spaced apart from said first location and downstream therefrom. In the third step, at least a portion of said second quantity of cooking liquor is reintroduced into the vessel at a third location upstream of said location of extraction of said second quantity of cooking liquor.
Another aspect of this invention relates to a digester including an upright generally cylindrical vessel having a top end and a bottom end for implementation of the improved method. The digester comprises a first conduit in fluid communication with a first location positioned intermediate the top and bottom ends for selectively extracting a first quantity of cooking liquor from the vessel at the first location, said first location positioned upstream of a second location within the vessel where the cooking liquor has achieved substantially full cooking temperature. The digester also comprises a second conduit in fluid communication with a third location positioned intermediate the top and bottom ends and downstream from the first and second locations and in fluid communication with a fourth location positioned at, about or upstream from the first location. The second conduit selectively extracts a second quantity of cooking liquor from the vessel at the third location, conveys at least a portion of the extracted second quantity of cooking liquor to the fourth location and introduces at least a portion of the conveyed second quantity of cooking liquor into the vessel at the fourth location.
One or more advantages flow from this process and digestor. One advantage is reduced calcium carbonate scaling. The process modifications disclosed in the present invention can be tailored to a digester system such that net reduction in pulping energy requirement, in the form of medium or high pressure steam consumption, can be realized for more cost savings. Furthermore, when the content of dissolved solids in the process stream(s) added to the early stages of a cook is lower than in the liquor removed from the cooking system, washing of the cooked chips is generally improved, and a smaller amount of weak black liquid can be used in pulp washing. As a result a smaller amount of washing liquor used, a higher total solids is sent to evaporators and additional savings are realized from a lower steam demand in the weak black liquor evaporation. In addition, removal of calcium and other non-process elements, as well as certain extractives, from the early stages of a cook has been found to improve pulp brightness and bleachability. Thus the present invention also results in still more savings from a lower pulp bleaching cost as an additional benefit.
Yet another embodiment of this invention relates to a method for increasing through-put in a digester of the type comprising an upright generally cylindrical vessel having a top end and a bottom end. In the first step of this method, a first quantity of cooking liquor at a first location and at first flow rate is extracted from the vessel. In the second step, a second quantity of process liquor equal to or greater than the first quantity is continuously introduced into the vessel at a second location which is at, about or upstream of the first location at a second flow rate which is equal to or greater than the first flow. A benefit resulting from this embodiment of the present invention is an increase in the sustainable maximum digester production throughput in a continuous digester, by increasing the amount of liquor moving downward to provide a higher downward force on the chips inside the digester.
BRIEF DESCRIPTION OF FIGURES
FIG. 1 is a schematic representation of a typical single-vessel digester system and depicting key features of the system piping associated with the method of the present invention.
FIG. 2 is a schematic representation of a typical two-vessel digester system and depicting key features of the system piping associated with the method of the present invention.
FIG. 3 is a schematic representation as in FIG. 1 and including certain aspects of Example I of the specification.
FIG. 4 is a schematic representation as in FIG. 1 and including certain aspects of Example II of the specification.
FIG. 5 is a schematic representation as in FIG. 1 and including certain aspects of Example III of the specification.
FIG. 6 is a schematic representation as in FIG. 1 and depicting typical ranges of calcium concentration associated with the single-vessel digester.
DETAILED DESCRIPTION OF INVENTION
With reference to FIG. 1 , there is schematically depicted a typical single-vessel hydraulic continuous digester 12 suitable for use in carrying out the method of the present invention. The depicted digester 12 includes an upright generally cylindrical vessel 14 having a top end 16 where there is received a supply of wood chips and alkaline cooking liquor 18 and a bottom end 20 which includes a blow assembly 22 by means of which a stream 24 of cooked chips and spent cooking liquor (pulp) is removed from the vessel. In the depicted embodiment, intermediate the top and bottom ends of the vessel there are provided a wash circulation sub-system 28 , a lower extraction location 30 , a lower cook circulation sub-system 32 , an upper extraction location 34 , an upper cook circulation sub-system 36 , and a top circulation subsystem 38 .
At the bottom of the vessel, the removed pulp stream is sent to a first pulp washer (not shown) via 24 , and the washing filtrate 42 from the first pulp washer is often cooled in cooler 40 , “cold blow filtrate” 26 as commonly known in the art, and introduced to the bottom of the digester for cooling and washing the cooked chips above the blow assembly 22 . This filtrate is available for recirculation to the vessel, either with or without cooling, and with or without further treatment before or after having been mixed with a stream of white liquor (WL) 44 and/or black liquor extracted from the upper and/or lower extraction locations on the digester, and reintroduced into the vessel, such as at the top end of the vessel. In FIG. 1 , the key feature of the process piping involved in the method of the present invention is set forth as dashed lines. With reference to FIG. 2 , there is schematically depicted a typical two-vessel continuous digester 50 suitable for use in carrying out the method of the present invention. As depicted in FIG. 2 , the digester has associated therewith a upright generally cylindrical first vessel and second vessel, where the first vessel 80 having a top circulation sub-system 82 , a bottom circulation sub-system 84 and a liquor makeup sub-system 86 including a makeup-liquor pump 88 . This first vessel serves as a source of pretreated wood chips mixed with cooking liquor that may originate from any one or more sources such as cold blow filtrate 90 , and/or white liquor (WL) 92 . The wood chips are pretreated in this first vessel and discharged from the bottom end 94 of the first vessel, thence conveyed as a supply stream 96 to the top end of the second vessel. As desired, liquor extracted from the lower extraction location 68 on the second vessel may be added to the supply stream to the second vessel. In FIG. 2 , the key features of the process piping involved in the practice of the present invention is set forth as dashed lines.
The depicted digester 50 includes an upright generally cylindrical second vessel having a top end 54 where there is received a supply of wood chips and alkaline cooking liquor 56 and a bottom end 58 which includes a blow assembly 60 by means of which a stream 62 of cooked chips and spent cooking liquor (pulp) is removed from the vessel, such stream being sent to a pulp washer 9 not shown).
The washing filtrate from the pulp washer 64 , also known as cold blow filtrate in the art, may be cooled and sent to the bottom of the second vessel for cooling and washing the cooked chips above the blow assembly 60 . This cold blow filtrate is also available for recirculation to the first vessel 80 , either without further treatment or after having been mixed with a stream of white liquor 92 and conveyed into the first vessel. In the depicted embodiment of FIG. 2 , intermediate the top and bottom ends of the vessel there are provided a wash circulation sub-system 66 , a lower extraction location 68 , and a trim circulation sub-system 70 . An upper extraction location 72 is associated with the trim circulation sub-system.
EXAMPLE I
The preferred embodiment of the method of the present invention was employed with the digester depicted in FIG. 1 . In this single-vessel continuous digester, cooking liquor rich in dissolved calcium of ˜40–120 ppm is withdrawn from the first row of screens of the upper cook circulation screen set at a flow rate of 0.10–0.50 (GPM for each ton per day production rate, or GPM/TPD) factor. (For example, for a pulp production rate of 750 tons per day, 0.1–0.5 times 750, yields 75–350 gallons per minute (GPM). A mixture of cold blow filtrate and wash extraction streams, the sum of which is about the same as the upper extraction flow and the concentration of dissolved calcium is less than 40 ppm, is added to the top of the digester via the makeup liquor pump. In this example, up to about 45% of the total dissolved calcium may be removed from the digester system, significantly reducing the tendency of calcium scaling on digester screens and cooking heaters.
EXAMPLE II
In a further example of the preferred embodiment of the method of the present invention, employing a single vessel digester as depicted in FIG. 1 , cooking liquor with ˜100 ppm dissolved calcium is withdrawn from the first row of screens of the upper cook circulation screen set at a flow rate of 0.35 (gallons per minute for each ton per day production rate, or GPM/TPD) factor, For example, for a pulp production rate of 750 tons per day, the extraction flow rate is 0.35 times 750, or ˜262 gallons per minute (GPM). A mixture of cold blow filtrate and wash extraction flows, the sum of which is about the same as the upper extraction flow and concentration of dissolved calcium is less that 40 ppm is added to the top of the digester via the makeup liquor pump. In this example, up to about 35% of the total dissolved calcium may be removed from the digester system, significantly reducing the tendency of calcium scaling on digester screens and cooking heaters.
EXAMPLE III
In a still further example employing the preferred embodiment of the method of the present invention, in a single vessel digester as depicted in FIG. 1 , cooking liquor rich in dissolved calcium of ˜100 ppm is withdrawn from the first row of screens of the upper cook circulation screen set at a flow rate of 0.35 gallons per minute for each ton per day production rate (GPM/TPD) factor. For example, for a pulp production rate of 750 tons per day, the flow rate is 0.35 times 750, or ˜262 gallons per minute (GPM). A cooking liquor taken from the wash circulation, at about the same flow rate with concentration of dissolved calcium less than 40 PPM, is added to the suction side of the upper cook circulation pump to replace the extracted calcium-rich cooking liquor, thus keeping the hydraulic balance of the digester. The upper circulation in this example is connected to the second (bottom) row of the upper cook screens. In this example, more than about 35% of the total dissolved calcium may be removed from the digester system, significantly reducing the tendency of calcium scaling on digester screens and cooking heaters.
The present method is operable with both hardwood pulp and softwood pulp.
Table I presents typical ranges of calcium concentrations in the cooking liquor in various locations in a digester as shown in FIG. 6 .
TABLE I
Process Point
Calcium (ppm)
White liquor (WL)
10–30
Impregnation vessel/zone,
40–120
(before the first heating circulation)
Between heating and full
20–60
cooking temperature
More than 60 minutes after
5–20
reaching full cooking temperature
Cold blow (washing) filtrate
10–40
Employing these calcium concentration ranges, one skilled in the art may readily determine the optimal locations at which cooking liquor may be extracted from the digester and where makeup liquor of lesser calcium concentration should be introduced to the digester.
In as much as the dissolved calcium concentration in a cooking liquor may vary as a function of the initial carbonate ion concentration, a significant amount of the cooking liquor should be withdrawn around the process point where the dissolved calcium concentration peaks. At what cooking temperature (corresponding to a certain digester location) the dissolved calcium concentration peaks depends on the carbonate concentration in the liquor. The higher the initial carbonate concentration in the liquor, the earlier the dissolved calcium concentration peaks within the digester.
Logistically, the preferred location in the digester for replacing a cooking liquor high in dissolved calcium with a liquor low in dissolved calcium is the first set of cooking circulation screens in a single-vessel continuous digester. Similarly the most suitable location to replace the extracted calcium-rich liquor with a liquor low in dissolved calcium is the chip transfer line (bottom circulation as known in the art) leading into the digester (the second vessel in FIG. 2 ) or the first set of screens immediately after the transfer line in a two-vessel continuous digester system.
Alternatively, (1) one may extract a sufficient amount of one of the process streams from a process point in a continuous digester that is located at least several minutes after full cooking temperature is reached, adding this process stream to an early stage of the cook, e.g. the feeding system or the bottom circulation, and extract an optimal amount of cooking liquor downstream of the addition point and upstream of the process point where full cooking temperature is reached
Further, same as Item (1) above, except that the temperature of the added process stream may be controlled by use of a heat exchanger, such that a desire pulping temperature profile is maintained.
Still further, same as Item (1) above, except that more than one process stream may be extracted from different process points after full cooking temperature is reached and that the temperature of one or more of the streams may be controlled by the use of one or more heat exchangers.
Another significant benefit, namely an increased maximum sustainable pulp production, is achieved from another preferred embodiment of the present invention. According to this embodiment, the upper extraction flow rate described in Examples I–III above (also depicted in FIGS. 3–5 ) is controlled to be significantly lower than the flow rate of the cooking liquor or a mixture of cold blow filtrate and a cooking liquor low in dissolved calcium, such that the amount of liquor (expressed as flow rate) around the chips in a digester, and thus the downward force acting on the chips, is significantly increased. This increased downward force acting on the chips results in a more stable chip column movement, and an increased maximum sustainable digester pulp production if column movement has been the limiting factor in obtaining a higher maximum digester pulp production.
Other variations in the method of the present invention will be recognized by one skilled in the art and the invention is to be limited only as set forth in the claims appended hereto.
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One aspect of this invention relates to a method and digester for reducing the deposition of calcium-based scale in a wood chip digester including extraction from the digester of first and second quantities of cooking liquor having respective first and second calcium concentrations, treating the extracted cooking liquors to produce a cooking liquor having a calcium concentration less that the calcium concentration of the either of the first and second extracted cooking liquors, and, reintroducing the treated cooking liquor to the digester. Another aspect of this invention relates to a method and digester in which through put through the digester is increased by the continuous addition of process liquor into the digester preferably at an upper region of the digester.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a transgenic C. elegans which expresses an amyloid precursor protein (APP) or a part thereof, to the transgene itself, to the protein encoded by the transgene, and also to a process for preparing the transgenic C. elegans and to its use.
[0003] 2. Description of Related Art
[0004] Several publications are referenced in the application. These references describe the state of the art to which this invention pertains, and are incorporated herein by reference.
[0005] Alzheimer's disease (morbus Alzheimer) is a neurodegenerative disorder of the brain which, at the cellular level, is accompanied by a massive loss of neurons in the limbic system and in the cerebral cortex. At the molecular level, it is possible to detect protein depositions, so-called plaques, in the affected areas of the brain, which depositions constitute an important feature of Alzheimer's disease. The protein which most frequently occurs in these plaques is a peptide of from 40 to 42 amino acids in size which is termed the Aβ peptide. This peptide is a cleavage product of a substantially larger protein of from 695 to 751 amino acids, the so-called amyloid precursor protein (APP).
[0006] APP is an integral transmembrane protein which traverses the lipid double layer once. By far the largest part of the protein is located extracellularly, while the shorter C-terminal domain is directed into the cytosol (FIG. 1). The Aβ peptide is shown in dark gray in FIG. 1. About two thirds of the Aβ peptide are derived from the extracellular domain of APP and about one third from the transmembrane domain.
[0007] In addition to the APP which is located in the membrane, it is also possible to detect a secreted form of the amyloid precursor protein, which form comprises the large ectodomain of the APP and is termed APPsec (“secreted APP”). APPsec is formed from APP by proteolytic cleavage which is effected by α-secretase. The proteolytic cleavage takes place at a site in the amino acid sequence of APP which lies within the amino acid sequence of the Aβ peptide (after amino acid residue 16 of the Aβ peptide). Proteolysis of APP by the α-secretase consequently rules out the possibility of the Aβ peptide being formed.
[0008] The Aβ peptide can consequently only be formed from APP by an alternative processing route. It is postulated that two further proteases are involved in this processing route, with one of the proteases, which is termed β-secretase, cutting the APP at the N terminus of the Aβ peptide and the second protease, which is termed γ-secretase, releasing the C terminus of the Aβ peptide (Kang, J. et al., Nature, 325, 733) (FIG. 1).
[0009] It has not as yet been possible to identify any of the three secretases or proteases (α-secretase, β-secretase and γ-secretase). However, knowledge of the secretases is of great interest, in particular within the context of investigations with regard to Alzheimer's disease and with regard to identifying the proteins involved, which proteins can then in turn be employed as targets in follow-up studies since, on the one hand, inhibition of the β-secretase, and in particular of the γ-secretase, could lead to a decrease in Aβ production and, on the other hand, activation of the α-secretase would increase the processing of APP into APPsec and thereby simultaneously reduce formation of the Aβ peptide.
[0010] There is a large amount of evidence that the Aβ peptide is a crucial factor in the development of Alzheimer's disease. Inter alia, Aβ fibrils are postulated to be neurotoxic in cell culture (Yankner, B. A. et al., (1990) Proc Natl Acad Sci USA,87, 9020). Furthermore, the neuropathology which is characteristic of Alzheimer's disease already appears at the age of 30 in Down's syndrome patients, who have an additional copy of APP. In this case, it is assumed that overexpression of APP is followed by an increased conversion into the Aβ peptide (Rumble, B. et al., (1989), N. Engl. J. Med., 320,1446).
[0011] The familial forms of Alzheimer's disease constitute what is probably the most powerful evidence of the central role of the Aβ peptide. In these forms, there are mutations in the APP gene around the region of the β-secretase and γ-secretase cleavage sites or in two further AD-associated genes (presenilins) which, in cell culture, lead to a substantial increase in Aβ production (Scheuner, D. et al., (1996), Nature Medicine, 2, 864).
[0012] While C. elegans has already been used as a model organism in Alzheimer's disease, these studies do not relate to the processing of APP into the Aβ peptide. Some of the studies are concerned with two other Alzheimer-associated proteins, i.e. the presenilins. The presenilins are transmembrane proteins which traverse the membrane 6-8 times. They are of great importance in familial cases of Alzheimers since specific mutations in the presenilin genes lead to Alzheimer's disease. In this connection, it was shown that homologs to the human presenilins (sel-12, spe-4 and hop-1) are present in C. elegans , with the function of the presenilins being conserved in humans and worm (Levitan D, Greenwald I (1995) Nature 377, 351; Levitan et al.(1996) Proc Natl Acad Sci USA, 93, 14940; Baumeister R (1997) Genes & Function 1, 149; Xiajun Li and Iva Greenwald (1997) Proc Natl Acad Sci USA, 94, 12204).
[0013] Other studies deal with the APP homolog in C. elegans, which is termed Apl-1, and with expression of the Aβ peptide in C. elegans. However, Apl-1 does not possess any region which is homologous with the amino acid sequence of the Aβ peptide; C. elegans does not therefore possess any endogenous Aβ peptide (Daigle I, Li C (1993) Proc Natl Acad Sci USA, 90 (24), 12045).
[0014] C. D. Link, Proc Natl Acad Sci USA (1995) 92, 9368 described the expression of Aβ peptide (but not that of an Aβ precursor protein) in C. elegans. These studies involve preparing transgenic worms which express an Aβ1-42 peptide (i.e. the Aβ peptide which consists of 42 amino acids) as a fusion protein together with a synthetic signal peptide and under the control of the muscle-specific promoter unc 54. Muscle-specific protein depositions which reacted with anti-β-amyloid antibodies were detected in the studies.
[0015] Other studies (e.g. C. Link et al. personal communication) relate to investigations of the aggregation and toxicity of the Aβ peptide in the C. elegans model system.
[0016] Transgenic C. elegans lines were established in the present study in order to investigate the existence of a processing machinery in C. elegans which is involved in the formation of Aβ peptide and to identify potential secretases in this worm.
SUMMARY OF THE INVENTION
[0017] In this invention, APP genes have been transferred into C. elegans to create a transgenic C. elegans organism. This transgenic C. elegans can then be used to investigate the processing machinery involved in the formation of the Aβ peptide and to identify potential secretases.
[0018] The present invention relates to a transgene (a gene that has been transferred from one species to another by genetic engineering) which contains
[0019] a) a nucleotide sequence encoding an amyloid precursor protein (APP) or a part thereof, wherein the nucleotide sequence comprising the APP peptide or part thereof, contains, as part of the sequence, a nucleotide sequence comprising a complete Aβ peptide or a part of the Aβ peptide, and
[0020] b) where appropriate, one or more further coding and/or non-coding nucleotide sequences, and
[0021] c) a promoter for expression in a cell of the nematode Caenorhabditis elegans ( C. elegans ).
[0022] The nucleotide sequence preferably encodes the 100 carboxyterminal amino acids of APP, beginning with the sequence of the Aβ peptide and ending with the carboxyterminal amino acid of APP (C100 fragment). The APP is preferably one of the isoforms APP695 (695 amino acids), APP751 (751 amino acids), APP770 (770 amino acids) and L-APP. All the isoforms are formed from the same APP gene by means of alternative splicing. In APP695, exons 7 and 8 were removed by splicing, whereas only exon 8 is lacking in APP751 and exon 7 and 8 are present in APP770. In addition to this, other splicing forms of APP exist in which exon 15 has been removed by splicing. These forms are termed L-APP and are likewise present in the forms which are spliced with regard to exons 7 and 8.
[0023] In one particular embodiment of the invention, the transgene contains the nucleotide sequence SEQ ID NO.: 1 or a part thereof or a sequence homologous to SEQ ID No. 1.
[0024] The transgene can preferably contain an additional coding nucleotide sequence which is located at the 5′ end of the nucleotide sequence encoding APP or a part thereof. In one particular embodiment of the invention, the additional nucleotide sequence encodes a signal peptide or a part thereof, for example encodes the APP signal peptide (SP) having the amino acid sequence SEQ ID NO.:9 or a part thereof. The sequence from the N terminus of the Aβ peptide to the C terminus of APP consists of 99 amino acids. The APP signal peptide consists of 17 amino acids. When a fusion product comprising the N terminus of the Aβ peptide to the C terminus of APP and the APP signal peptide is cloned, one or more spacer amino acids is/are preferably inserted between these two parts of the fusion product, with preference being given to inserting one amino acid, for example leucine. The C-terminal fragment is therefore given different designations, e.g. C100 (C=C terminus), LC99 (L=leucine), LC1-99, C99 or SPA4CT (SP=signal peptide, A4=Aβ peptide and CT=C terminus).
[0025] In one particular embodiment of the invention, the transgene contains the nucleotide sequence SEQ ID NO.: 2 or a part thereof and/or the nucleotide sequence SEQ ID NO.: 3 or a part thereof.
[0026] In addition to this, the transgene can also contain one or more additional non-coding and/or one or more additional coding nucleotide sequences.
[0027] For example, the transgene can contain, as an additional non-coding nucleotide sequence, a sequence from an intron of the APP gene, e.g. a sequence which is derived from the 42 bp intron of the APP gene and exhibits the sequence SEQ ID NO.: 4. A transgene which contains the nucleotide sequence SEQ ID NO.: 5 is part of the subject-matter of the invention.
[0028] The transgene also preferably contains one or more gene-regulating sequences for regulating expression of the encoded protein, preferably a constitutive promoter or a promoter which can be regulated. For example, the promoter can be active in the neuronal, muscular or dermal tissue of C. elegans or be ubiquitously active in C. elegans. A promoter can, for example, be selected from the group of the C. elegans promoters unc-54, hsp 16-2, unc-119, goa-1 and sel-12. In one particular embodiment of the invention, the transgene contains a promoter having the nucleotide sequence SEQ ID NO.: 6. In one particular embodiment, the transgene contains the nucleotide sequence SEQ ID NO.: 7.
[0029] The transgene can be present in a vector, for example in an expression vector. For example, a recombinant expression vector can contain the nucleotide sequence SEQ ID NO.: 8.
[0030] The invention also relates to the preparation of an expression vector, with a transgene being integrated into a vector in accordance with known methods. In particular, the invention relates to the use of an expression vector for preparing a transgenic cell, with it being possible for this cell to be part of a non-human organism, e.g. C. elegans.
[0031] The invention also relates to the preparation of the transgene, with suitable part sequences being ligated in the appropriate order and in the correct reading frame, where appropriate while inserting linkers. In particular, the invention relates to the use of the transgene, for example for preparing a transgenic cell, with it being possible for this cell to be part of a non-human organism. For example, the cell can be a C. elegans cell.
[0032] One particular embodiment of the invention relates to a transgenic C. elegans which contains the transgene. The transgene can also be present in the C. elegans in an expression vector. The transgene can be present in the C. elegans intrachromosomally and/or extrachromosomally. One or more transgenes or expression vectors which contain the transgene can be present intrachromosomally and/or extrachromosomally as long tandem arrays. A transgenic cell or a transgenic organism preferably contains another expression vector as well, which vector contains a nucleotide sequence which encodes a marker, with the marker either being a temperature-sensitive marker or a phenotypic marker. For example, the marker can be a visual marker or a behaviorally phenotypic marker. Examples are fluorescent markers, e.g. GFP (green fluorescent protein) or EGFP (enhanced green fluorescent protein), marker genes which encode a dominant, mutated form of a particular protein, e.g. a dominant Rol6 mutation, or marker sequences which encode antisense RNA, e.g. the antisense RNA of Unc-22.
[0033] One or more copies of the transgene and/or of the expression vector and, where appropriate, of an additional expression vector are preferably present in the germ cells and/or the somatic cells of the transgenic C. elegans.
[0034] The invention also relates to a process for preparing a transgenic C. elegans, with a transgene and/or an expression vector, where appropriate in the presence of an additional expression vector which contains a nucleotide sequence which encodes a marker, being microinjected into the germ cells of a C. elegans. A DNA construct which expresses SP-C100 (SP=signal peptide) under the control of a neuron-specific promoter can, for example, be used for preparing the transgenic C. elegans lines (FIG. 2). Since C100 is composed of the Aβ sequence and the C terminus of APP, only the γ-secretase cleavage is required in order to release the Aβ peptide from C100. C100 is also a substrate for the γ-secretase.
[0035] The invention also relates to the use of a transgenic C. elegans, for example for expressing an SP-C100 fusion protein. An SP-C100 fusion protein having the amino acid sequence SEQ ID NO.: 10 is part of the subject-matter of the invention.
[0036] In particular, the invention relates to the use of a transgenic C. elegans for identifying a γ-secretase activity and/or an α-secretase activity in C. elegans, to its use in methods for identifying and/or characterizing substances which inhibit the γ-secretase activity, to its use in methods for identifying and/or characterizing substances which increase the α-secretase activity, and to its use in methods for identifying and/or characterizing substances which can be used as active compounds for treating and/or preventing Alzheimer's disease.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0037] In the present study, the nematode Caenorhabditis elegans ( C. elegans ) was chosen as the model organism for identifying secretases which are involved in processing APP into the Aβ peptide. This worm is outstandingly suitable for genetic studies and has therefore in the past been employed on many occasions for investigating universally important processes such as programmed cell death, neuronal guidance and RAS/MAP kinase signaling (Riddle, D. L. et al. (1997) ).
[0038] The important points which make C. elegans especially appropriate for such studies include the following (C. Kenyon, Science (1988) 240, 1448; P. E. Kuwabara (1997), TIG, 13, 454):
[0039] Its small genome, which is composed of about 19,000 genes or 97 Mb and which was sequenced completely in December 1998. (The C. elegans Sequencing Consortium, Science (1998), 282, 2012).
[0040] Its reproduction by self fertilization. In the case of the two sexes of C. elegans, a distinction is made between males and hermaphrodites, i.e. hermaphroditic animals which fertilize their eggs themselves before laying. A crucial advantage of this type of reproduction is that, after a transgene has been introduced into the germ line, a hermaphrodite can automatically generate homozygous transgenic descendants. There is therefore no need for any further crossing steps, as in the case of Drosophila, for example, for preparing transgenic lines.
[0041] Its easy handling in the laboratory due to its small size (about 1 mm in length) and its relatively undemanding growth conditions. As a result, a large number of worms can be handled routinely in the laboratory.
[0042] Its short generation time of 3 days, which makes it possible to obtain large quantities of biological material for analysis within a very short time.
[0043] A complete cell description for the development and anatomy of C. elegans is available.
[0044] Detailed genetic maps and methods for genetic analysis in C. elegans are available.
[0045] Technologies for preparing knock-out animals are available. In the same way, technologies exist for mutagenizing the C. elegans genome (transposon mutagenesis and ethyl methanesulfonate (EMS) mutagenesis).
[0046] The following are possible uses of the transgenic C. elegans lines:
[0047] 1. Identification of a γ-secretase-like activity in C. elegans using mutagenesis approaches. It is planned that a transposon mutagenesis, which destroys the γ-secretase-like activity, should be carried out and that the corresponding gene should be sought by detecting the worms which no longer possess this activity. Such a screening method is described in the literature: Korswagen H. C. et al., (1996), 93, 14680 Proc Natl Acad Sci USA.
[0048] Alternative approaches would be mutagenesis using ethyl methanesulfonate (EMS) or else anti-sense RNA approaches. In the latter case, an attempt could be made to find motifs which were common to all C. elegans proteases and to downregulate these proteases specifically using anti-sense RNAs which were directed against these motifs. Screening for the Aβ peptide could then show whether one of the proteases was involved in Aβ peptide production.
[0049] 2. Identification of a γ-secretase-like activity in C. elegans, perhaps by a similar route to that described in item 1.
[0050] 3. Armed with knowledge of a γ-secretase or γ-secretase-like activity in C. elegans, it is possible to search for human γ-secretase or γ-secretase-like activity by means of a homology comparison.
[0051] 4. Identification of drugs which
[0052] inhibit the activity of γ-secretase, in order to inhibit Aβ production from the amyloid precursor protein directly.
[0053] activate γ-secretase and thereby indirectly inhibit formation of the Aβ peptide by increasing APPsec production.
[0054] This approach could take place in a 96-well format since C. elegans can be maintained in suspension in 96-well plates.
[0055] Since the screening is carried out on a whole organism, it is possible, to a large extent, to exclude drugs which have an unspecific toxic effect.
[0056] 5. Investigation of the aggregation behavior, and of a possible neurotoxic effect, of the Aβ peptide in C. elegans. Screening for drugs which inhibit aggregation of the Aβ peptide.
[0057] 6. Investigation of the modulation of APP processing by other proteins (e.g. presenilins or ApoE) as a result of their overexpression or knock-out. Since the presenilins are Alzheimer-associated proteins and ApoE constitutes a risk factor in Alzheimer's disease, these proteins could have an effect on formation of the Aβ peptide and, as a consequence, their role in the APP processing pathway could be investigated.
[0058] 7. Where appropriate, validation of an α-secretase and/or γ-secretase activity which has been found using other experimental approaches known to the skilled person.
[0059] [0059]FIG. 1: FIG. 1 shows the amyloid precursor protein (APP695 isoform and APP770 and APP751 isoforms) and secretase cleavage products.
[0060] [0060]FIG. 2: FIG. 2 describes the construction of the transgenic vector “Unc-119-SP-C100”, which contains an unc-119 promoter, an APP signal peptide and the C100 fragment from APP, with “unc-119” being a neuron-specific C. elegans promoter, the APP signal peptide corresponding to amino acids 1 to 24 of APP and C100 corresponding to the 100 C-terminal amino acids of APP (=C100). C100 is composed of the Aβ sequence and the C terminus of APP (Shoji, M et al., (1992) Science 258, 126). The vector Unc-119-SP-C100 possesses 5112 base pairs.
EXAMPLES
[0061] The following examples are illustrative of some of the products and compositions and methods of making and using the same falling within the scope of the present invention.
[0062] Example 1
Preparing an Expression Vector Which Contains the Transgene
[0063] Two vectors, i.e. pSKLC1-99, which encodes SP-C100, and pBY103, which contains the unc-119 promoter, were used for the cloning, with the SP-C100-encoding DNA being cloned into the pBY103 vector behind the unc-119 promoter. The basic vector pBY103 is composed of the vector backbone pPD49.26, which is described in “ Caenorhabditis elegans: Modern Biological Analysis of an Organism” (1995) Ed. Epstein et al., Vol 48, pp. 473, into which the unc-119 promoter (Maduro et al. Genetics (1995) , 141, p. 977) has been cloned by way of the HindIII/BamHI sites. The plasmid unc-119-SP-C100 was prepared by KpnI/SacI digestion of pSKLC1-99 and cloning of the LC99 fragment into pBY103 (Shoji et al. (1992).
Example 2
Preparing the Transgenic C. elegans Lines
[0064] The method of microinjection was used for preparing the transgenic C. elegans lines (Mello et al., (1991) EMBO J. 10 (12) 3959; C. Mello and A. Fire, Methods in Cell Biology, Academic Press Vol. 48, pp. 451, 1995; C. D. Link, Proc Natl Acad Sci USA (1995) 92, 9368).
[0065] Two different C. elegans strains, i.e. wild-type N2 and him-8 (high incidence of males), were used. The unc-119-SP-C100 construct was microinjected into the gonads of young adult hermaphrodites using a microinjection appliance. The DNA concentration was about 20 ng/μl.
[0066] A marker plasmid was injected together with the unc-119-SP-C100 construct. This marker plasmid is the plasmid ttx3-GFP, which encodes the green fluorescent protein under the control of the ttx3 promoter. The activity of the ttx3 promoter is specific for particular neurons of the C. elegans head, the so-called AIY neurons, which play a role in the thermotaxis of the worm.
[0067] When plasmid DNA is microinjected, it is assumed that long tandem arrays, which are composed of many copies of plasmid DNA (in our case, of the ttx3-GFP plasmid and the unc-119-SP-C100 plasmid), are formed by recombination. A certain percentage of these arrays integrate into the C. elegans genome. However, the arrays are more likely to be present extrachromosomally.
[0068] Worms which had been injected successfully exhibit a green fluorescence in the AIY neurons of the head region when stimulated with light of a wavelength of about 480 nm. It was possible to detect such nematodes.
Example 3
Describing the C100 Transgenic C. elegans Lines
[0069] 1. Phenotypic Features
[0070] Following stimulation with light of a wavelength of 480 nm, C100-transgenic worms exhibit a green fluorescence in the AIY neurons of the head region. Since it was also possible to detect green fluorescence in the head neurons once again in the descendants of the worms, it can be assumed that the plasmids are able to pass down through the germ line. However, the penetrance is not 100%, which makes it possible to conclude that the long tandem arrays composed of ttx3-GFP marker DNA and unc-119-SP-C100 are present extrachromosomally rather than being integrated into the genome.
Example 4
Detecting C100 Expression in a Blot
[0071] Six different transgenic C100 C. elegans lines (three in an N2 wt background and three in a him 8 background) were examined in a Western blot for expression of the C100 fragment using a polyclonal antiserum directed against the C terminus of APP. A band having the appropriate molecular weight of about 10 kDa was detectable in all the six lines.
Example 5
Detecting the C100 in an ELISA
[0072] In an Aβ Sandwich ELISA, signals which were above the background level, and which were statistically significant in two cases, were detected in cell extracts from transgenic animals. This indicates that C. elegans could possess a γ-secretase-like activity.
[0073] In the Aβ Sandwich ELISA assay, 96-well plates are first of all incubated with the monoclonal antibody clone 6E10 (SENETEK PLC., MO, USA), which reacts specifically with the Aβ peptide (amino acids 1-17), and then coated with worm extracts from transgenic worms or control worms. The Aβ peptide is detected using the monoclonal Aβ antibody 4G8 (SENETEK PLC., MO, USA), which recognizes amino acids 17-24 in the Aβ peptide and is labeled with biotin. The detection is effected by way of the alkaline phosphatase reaction using an appropriate antibody which is directed against biotin. Disruption of the worms involves detergent treatment, nitrogen shock freezing, sonication and rupture of the cells using glass beads.
[0074] The ELISA signal from the above-described experiment can be based either on weak expression of the Aβ peptide or on expression of the C100 precursor protein, since the appropriate epitopes are present in both proteins.
[0075] Expression of the Aβ peptide could, for example, also be specifically detected in an analogous manner: for this, Aβ-specific antibodies which do not react with the C100 precursor would have to be employed in an Aβ Sandwich ELISA. An Aβ-specific antibody could, for example, be a monoclonal antibody which specifically recognizes the C-terminal end of the Aβ form, which is composed of 40 or 42 amino acids. In parallel, the Aβ peptide could be detected in a Western blot using the monoclonal antibodies 4G8 and 6E10 and then be distinguished from the larger C100 precursor by its molecular weight of 4 kD.
[0076] The vectors can be obtained from Andrew Fire (Department of Embryology, Carnegie Institution of Washington, Baltimore, Md. 21210, USA) in the case of pPD49.26 and LC99 (amyloid precursor protein), which is deposited under ATCC number 106372. The unc-119 promoter can be obtained from Maduro, M. (Department of Biological Science, Universitiy of Alberta Edmonton, Canada), while unc-54 and unc-16.2 can be obtained from Andrew Fire.
[0077] The above description of the invention is intended to be illustrative and not limiting. Various changes or modifications in the embodiments described may occur to those skilled in the art. These can be made without departing from the spirit or scope of the invention.
SEQ ID NO.1: Nucleotide sequence of C100 CTGGATGC AGAATTCCGA CATGACTCAG GATATGAAGT TCATCATCAAAAATTGGTGT TCTTTGCAGA AGATGTGGGT TCAAACAAAG GTGCAATCAT TGGACTCATGGTGGGCGGTG TTGTCATAGC GACAGTGATC GTCATCACCT TGGTGATGCT GAAGAAGAAACAGTACACAT CCATTCATCA TGGTGTGGTG GAGGTTGACG CCGCTGTCAC CCCAGAGGAGCGCCACCTGT CCAAGATGCA GCAGAACGGC TACGAAAATC CAACCTACAA GTTCTTTGAGCAGATGCAGA ACTAG SEQ ID NO.2: Nucleotide sequence of SP ATG CTGCCCGGTT TGGCACTGTT CCTGCTGGCC GCCTGGACGG CTCGGGCG SEQ ID NO.3: Nucleotide sequence of SP+C100 ATG CTGCCCGGTT TGGCACTGTT CCTGCTGGCC GCCTGGACGG CTCGGGCGCT G GATGC AGAATTCCGA CATGACTCAG GATATGAAGT TCATCATCAA AAATTGGTGT TCTTTGCAGA AGATGTGGGT TCAAACAAAG GTGCAATCAT TGGACTCATG GTGGGCGGTG TTGTCATAGC GACAGTGATC GTCATCACCT TGGTGATGCT GAAGAAGAAA CAGTACACAT CCATTCATCA TGGTGTGGTG GAGGTTGACG CCGCTGTCAC CCCAGAGGAG CGCCACCTGT CCAAGATGCA GCAGAACGGC TACGAAAATC CAACCTACAA GTTCTTTGAG CAGATGCAGA ACTAG SEQ ID NO.4: Nucleotide sequence of the 42bp intron GTATGTTTCGAATGATACTAACATAACATAGAACATTTTCAG SEQ ID NO.5: Nucleotide sequence of intron+SP+C100 GTATGTTTCGAATGATACTAACATAACATAGAACATTTTCAGGAGGACCCTTGGCTAGCGTCGACGGT ACCGGGCCCCCCCTCGAGGTCGACGGTATCGATAACCTTCACAGCAGCGCACTCGGTGCCCCGCG CAGGGTCGCGATG CTGCCCGGTT TGGCACTGTT CCTGCTGGCCGCCTGGACGG CTCGGGCGCT GGATGC AGAATTCCGAATGACTCAGGATATGAAGTCATCATCAAAAATTGGTGT TCTTTGCAGA AGATGTGGGT TCAAACAAAG GTGCAATCAT TGGACTCATG GTGGGCGGTG TTGTCATAGC GACAGTGATC GTCATCACCT TGGTGATGCT GAAGAAGAAA CAGTACACAT CCATTCATCA TGGTGTGGTG GAGGTTGACG CCGCTGTCAC CCCAGAGGAGCGCCACCTGT CCAAGATGCA GCAGAACGGC TACGAAAATC CAACCTACAA GTTCTTTGAG CAGATGCAGA ACTAG SEQ ID NO.6: Nucleotide sequence of unc-119 AAGCTTCAGTAAAAGAAGTAGAATTTTATAGTTTTTTTTCTGTTTGAAAAATTCTCCCCATCAATGTTCT TTCAAATAAATACATCACTAATGCAAAGTATTCTATAACCTCATATCTAAATTCTTCAAAATCTTAACAT ATC TTATCATTGCTTTAAGTCAACGTAACATTAAAAAAAATGTTTTGGAAAATGTGTCAAGTCTCTCAAAATT CAGTTTTTTAAACCACTCCTATAGTCCTATAGTCCTATAGTTACCCATGAAATCCTTATATATTACTGTA AAATGTTTCAAAAACCATTGGCAAATTGCCAGAACTGAAAATTTCCGGCAAATTGGGGAACCGGCAA ATTGCCAATTTGCTGAATTTGCCGGAAACGGTAATTGCCGAAAGTTTTTGACACGAAAATGGCAAATT GTGGTTTTAAAATTTTTTTTTTTGGAAATTTCAGAATTTCAATTTTAATCGGCAAAACTGTAGGCATCCT AAGAATGTTCCTACATCTATTTTGAAAAGTAAGCGAATTAATTCTATGAAAATGTCTAAAGAAAATGGG GAAACAATTTCAAAAAGGCACAGTTTCAATGGTTTCCGAATTATACTAAATCCCTCTAAAAACTTCCGG CAAATTGATATCCGTAAAAGAGCAAATCCGCATTTTTGCCGAAAATTAAAATTTCCGACAAATCGGCA AACCGGCAATTTGGCGAAATTTGCCGGAACGATTGCCGCCCACCCCTGTTCCAGAGGTTCAAACTG GTAGCAAAGCTCAAAATTTCTCAAATTCTCCAATTTTTTTTTGAATTTTGGCAGTGTACCAAAATGACA TTCAGTCATATTGGTTTATTATAGATTTATTTAGATAAAATCCTAAATGATTCTACCTTTAAAGATGCCC ACTTTAAAAGTAATGACTCAAACTTCAAATTGCTCTAAGATTCTATTGAATTACCATCTTTTCCTCTCAT TTTCTCTCACTGTCTATTTCATCACAAATTCATCCCTCTCTCCTCTCTTCTCTCTCCCTCTCTCTCTCTT TCTCTTTGCTCATCATCTGTCATTTTGTCCGTTCCTCTCTCTGCGCCCTCAGCGTTCCCCACACTCTC TCGCTTCTCTTTTCCTAGACGTCTTCTTTTTTCATCTTCTTCAGCCTTTTTCGCCATTTTCCATCTCTGT CAATCATTACGGACGACCCCCATTATCGAT SEQ ID NO.7: Nucleotide sequence of unc-119+intron+SP+C100 AAGCTTCAGTAAAAGAAGTAGAATTTTATAGTTTTTTTTCTGTTTGAAAAATTCTCCCCATCA ATGTTCTTTCAAATAAATACATCACTAATGCAAAGTATTCTATAACCTCATATCTAAATTCTTCAAAATC TTAACATATCTTATCATTGCTTTAAGTCAACGTAACATTAAAAAAAATGTTTTGGAAAATGTGTCAAGTC TCTCAAAATTCAGTTTTTTAAACCACTCCTATAGTCCTATAGTCCTATAGTTACCCATGAAATCCTTATA TATTACTGTAAAATGTTTCAAAAACCATTGGCAAATTGCCAGAACTGAAAATTTCCGGCAAATTGGGG AACCGGCAAATTGCCAATTTGCTGAATTTGCCGGAAACGGTAATTGCCGAAAGTTTTTGACACGAAAA TGGCAAATTGTGGTTTTAAAATTTTTTTTTTTGGAAATTTCAGAATTTCAATTTTAATCGGCAAAACTGT AGGCATCCTAAGAATGTTCCTACATCTATTTTGAAAAGTAAGCGAATTAATTCTATGAAAATGTCTAAA GAAAATGGGGAAACAATTTCAAAAAGGCACAGTTTCAATGGTTTCCGAATTATACTAAATCCCTCTAA AAACTTCCGGCAAATTGATATCCGTAAAAGAGCAAATCCGCATTTTTGCCGAAAATTAAAATTTCCGA CAAATCGGCAAACCGGCAATTTGGCGAAATTTGCCGGAACGATTGCCGCCCACCCCTGTTCCAGAG GTTCAAACTGGTAGCAAAGCTCAAAATTTCTCAAATTCTCCAATTTTTTTTTGAATTTTGGCAGTGTAC CAAAATGACATTCAGTCATATTGGTTTATTATAGATTTATTTAGATAAAATCCTAAATGATTCTACCTTT AAAGATGCCCACTTTAAAAGTAATGACTCAAACTTCAAATTGCTCTAAGATTCTATTGAATTACCATCT TTTCCTCTCATTTTCTCTCACTGTCTATTTCATCACAAATTCATCCCTCTCTCCTCTCTTCTCTCTCCCT CTCTCTCTCTTTCTCTTTGCTCATCATCTGTCAT TTTGTCCGTTCCTCTCTCTGCGCCCTCAGCGTTCCCCACACTCTCTCGCTTCTCTTTTCCTAGACGTC TTCTTTTTTCATCTTCTTCAGCCTTTTTCGCCATTTTCCATCTCTGTCAATCATTACGGACGACCCCCA TTATCGATAAGATCTCCACGGTGGCCGCGAATTCCTGCAGCCCGGGGGATCCCCGGGATTGGCCAA AGGACCCAAAGGTATGTTTCGAATGATACTAACATAACATAGAACATTTTCAGGAGGACCCTTGGCTA GCGTCGACGGTACCGGGCCCCCCCTCGAGGTCGACGGTATCGATAACCTTCACAGCAGCGCACTC GGTGCCCCGCGCAGGGTCGCGATGCTGCCCGGTT TGGCACTGTTCCTGCTGGCCGCCTGGACGGCTCGGGCGCTGGATGCAGAATTCCGA CATGACTCAGGATATGAAGTTCATCATCAAAAATTGGTGTTCTTTGCAGAAGATGTGGGTTCAAACAA AG GTGCAATCAT TGGACTCATGGTGGGCGGTGTTGTCATAGCGACAGTGATCGTCATCACCT TGGTGATGCT GAAGAAGAAACAGTACACAT CCATTCATCA TGGTGTGGTG GAGGTTGACG CCGCTGTCAC CCCAGAGGAGCGCCACCTGT CCAAGATGCA GCAGAACGGC TACGAAAATC CAACCTACAA GTTCTTTGAGCAGATGCAGA ACTAG SEQ ID NO.8: Nucleotide sequence of the expression vector ACCCCCGCCACAGCAGCCTCTGAAGTTGGACACGGATCCACTAGTTCTAGAGCGGCCGCCACCGC GGTGGAGCTCCGCATCGGCCGCTGTCATCAGATCGCCATCTCGCGCCCGTGCCTCTGACTTCTAAG TCCAATTACTCTTCAACATCCCTACATGCTCTTTCTCCCTGTGCTCCCACCCCCTATTTTTGTTATTAT CAAAAAAACTTCTTCTTAATTTCTTTGTTTTTTAGCTTCTTTTAAGTCACCTCTAACAATGAAATTGTGT AGATTCAAAAATAGAATTAATTCGTAATAAAAAGTCGAAAAAAATTGTGCTCCCTCCCCCCATTAATAA TAATTCTATCCCAAAATCTACACAATGTTCTGTGTACACTTCTTATGTTTTTTTTACTTCTGATAAATTTT TTTTGAAACATCATAGAAAAAACCGCACACAAAATACCTTATCATATGTTACGTTTCAGTTTATGACCG CAATTTTTATTTCTTCGCACGTCTGGGCCTCTCATGACGTCAAATCATGCTCATCGTGAAAAAGTTTT GGAGTATTTTTGGAATTTTTCAATCAAGTGAAAGTTTATGAAATTAATTTTCCTGCTTTTGCTTTTTGGG GGTTTCCCCTATTGTTTGTCAAGAGTTTCGAGGACGGCGTTTTTCTTGCTAAAATCACAAGTATTGAT GAGCACGATGCAAGAAAGATCGGAAGAAGGTTTGGGTTTGAGGCTCAGTGGAAGGTGAGTAGAAGT TGATAATTTGAAAGTGGAGTAGTGTCTATGGGGTTTTTGCCTTAAATGACAGAATACATTCCCAATATA CCAAACATAACTGTTTCCTACTAGTCGGCCGTACGGGCCCTTTCGTCTCGCGCGTTTCGGTGATGAC GGTGAAAACCTCTGACACATGCAGCTCCCGGAGACGGTCACAGCTTGTCTGTAAGCGGATGCCGGG AGCAGACAAGCCCGTCAGGGCGCGTCAGCGGGTGTTGGCGGGTGTCGGGGCTGGCTTAACTATGC GGCATCAGAGCAGATTGTACTGAGAGTGCACCATATGCGGTGTGAAATACCGCACAGATGCGTAAG GAGAAAATACCGCATCAGGCGGCCTTAAGGGCCTCGTGATACGCCTATTTTTATAGGTTAATGTCAT GATAATAATGGTTTCTTAGACGTCAGGTGGCACTTTTCGGGGAAATGTGCGCGGAACCCCTATTTGT TTATTTTTCTAAATACATTCAAATATGTATCCGCTCATGAGACAATAACCCTGATAAATGCTTCAATAAT ATTGAAAAAGGAAGAGTATGAGTATTCAACATTTCCGTGTCGCCCTTATTCCCTTTTTTGCGGCATTTT GCCTTCCTGTTTTTGCTC ACCCAGAAACGCTGGTGAAAGTAAAAGATGCTGAAGATCAGTTGGGTGCACGAGTGGGTTACATCG AACTGGATCTCAACAGCGGTAAGATCCTTGAGAGTTTTCGCCCCGAAGAACGTTTTCCAATGATGAG CACTTTTAAAGTTCTGCTATGTGGCGCGGTATTATCCCGTATTGACGCCGGGCAAGAGCAACTCGGT CGCCGCATACACTATTCTCAGAATGACTTGGTTGAGTACTCACCAGTCACAGAAAAGCATCTTACGG ATGGCATGACAGTAAGAGAATTATGCAGTGCTGCCATAACCATGAGTGATAACACTGCGGCCAACTT ACTTCTGACAACGATCGGAGGACCGAAGGAGCTAACCGCTTTTTTGCACAACATGGGGGATCATGTA ACTCGCCTTGATCGTTGGGAACCGGAGCTGAATGAAGCCATACCAAACGACGAGCGTGACACCACG ATGCCTGTAGCAATGGCAACAACGTTGCGCAAACTATTAACTGGCGAACTACTTACTCTAGCTTCCC GGCAACAATTAATAGACTGGATGGAGGCGGATAAAGTTGCAGGACCACTTCTGCGCTCGGCCCTTC CGGCTGGCTGGTTTATTGCTGATAAATCTGGAGCCGGTGAGCGTGGGTCTCGCGGTATCATTGCAG CACTGGGGCCAGATGGTAAGCCCTCCCGTATCGTAGTTATCTACACGACGGGGAGTCAGGCAACTA TGGATGAACGAAATAGACAGATCGCTGAGATAGGTGCCTCACTGATTAAGCATTGGTAACTGTCAGA CCAAGTTTACTCATATATACTTTAGATTGATTTAAAACTTCATTTTTAATTTAAAAGGATCTAGGTGAAG ATCCTTTTTGATAATCTCATGACCAAAATCCCTTAACGTGAGTTTTCGTTCCACTGAGCGTCAGACCC CGTAGAAAAGATCAAAGGATCTTCTTGAGATCCTTTTTTTCTGCGCGTAATCTGCTGCTTGCAAACAA AAAAACCACCGCTACCAGCGGTGGTTTGTTTGCCGGATCAAGAGCTACCAACTCTTTTTCCGAAGGT AACTGGCTTCAGCAGAGCGCAGATACCAAATACTGTCCTTCTAGTGTAGCCGTAGTTAGGCCACCAC TTCAAGAACTCTGTAGCACCGCCTACATACCTCGCTCTGCTAATCCTGTTACCAGTGGCTGCTGCCA GTGGCGATAAGTCGTGTCTTACCGGGTTGGACTCAAGACGATAGTTACCGGATAAGGCGCAGCGGT CGGGCTGAACGGGGGGTTCGTGCACACAGCCCAGCTTGGAGCGAACGACCTACACCGAACTGAGA TACCTACAGCGTGAGCATTGAGAAAGCGCCACGCTTCCCGAAGGGAGAAAGGCGGACAGGTATCCG GTAAGCGGCAGGGTCGGAACAGGAGAGCGCACGAGGGAGCTTCCAGGGGGAAACGCCTGGTATCT TTATAGTCCTGTCGGGTTTCGCCACCTCTGACTTGAGCGTCGATTTTTGTGATGCTCGTCAGGGGGG CGGAGCCTATGGAAAAACGCCAGCAACGCGGCCTTTTTACGGTTCCTGGCCTTTTGCTGGCCTTTTG CTCACATGTTCTTTCCTGCGTTATCCCCTGATTCTGTGGATAACCGTATTACCGCCTTTGAGTGAGCT GATACCGCTCGCCGCAGCCGAACGACCGAGCGCAGCGAGTCAGTGAGCGAGGAAGCGGAAGAGC GCCCAATACGCAAACCGCCTCTCCCCGCGCGTTGGCCGATTCATTAATGCAGCTGGCACGACAGGT TTCCGGACTGGAAAGCGGGCAGTGAGCGCAACGCAATTAATGTGAGTTAGCTCACTCATTAGGCAC CCCAGGCTTTACACTTTATGCTTCCGGCTCGTATGTTGTGTGGAATTGTGAGCGGATAACAATTTCAC ACAGGAAACAGCTATGACCATGATTACGCCAAGCTT SEQ ID NO.9: Amino acid sequence of SP MLPGLALFLL AAWTARA SEQ ID NO.10: Amino acid sequence of the fusion protein MLPGLALFLL AAWTARALDA EFRHDSGYEV HHQKLVFFAE DVGSNKGAII GLMVGGVVIA TVIVITLVML KKKQYTSIHH GVVEVDAAVT PEERHLSKMQ QNGYENPTYK FFEQMQN SEQ ID NO. 11: Nucleotide sequence of the vector unc-119-SP-C100 ATGACCATGATTACGCCAAGCTTCAGTAAAAGAAGTAGAATTTTATAGTTTTTTTTCTGTTTGAAAAAT TCTCCCCATCAATGTTCTTTCAAATAAATACATCACTAATGCAAAGTATTCTATAACCTCATATCTAAAT TCTTCAAAATCTTAACATATCTTATCATTGCTTTAAGTCAACGTAACATTAAAAAAAATGTTTTGGAAAA TGTGTCAAGTCTCTCAAAATTCAGTTTTTTAAACCACTCCTATAGTCCTATAGTCCTATAGTTACCCAT GAAATCCTTATATATTACTGTAAAATGTTTCAAAAACCATTGGCAAATTGCCAGAACTGAAAATTTCCG GCAAATTGGGGAACCGGCAAATTGCCAATTTGCTGAATTTGCCGGAAACGGTAATTGCCGAAAGTTT TTGACACGAAAATGGCAAATTGTGGTTTTAAAATTTTTTTTTTTGGAAATTTCAGAATTTCAATTTTAAT CGGCAAAACTGTAGGCATCCTAAGAATGTTCCTACATCTATTTTGAAAAGTAAGCGAATTAATTCTAT GAAAATGTCTAAAGAAAATGGGGAAACAATTTCAAAAAGGCACAGTTTCAATGGTTTCCGAATTATAC TAAATCCCTCTAAAAACTTCCGGCAAATTGATATCCGTAAAAGAGCAAATCCGCATTTTTGCCGAAAA TTAAAATTTCCGACAAATCGGCAAACCGGCAATTTGGCGAAATTTGCCGGAACGATTGCCGCCCACC CCTGTTCCAGAGGTTCAAACTGGTAGCAAAGCTCAAAATTTCTCAAATTCTCCAATTTTTTTTTGAATT TTGGCAGTGTACCAAAATGACATTCAGTCATATTGGTTTATTATAGATTTATTTAGATAAAATCCTAAAT GATTCTACCTTTAAAGATGCCCACTTTAAAAGTAATGACTCAAACTTCAAATTGCTCTAAGATTCTATT GAATTACCATCTTTTCCTCTCATTTTCTCTCACTGTCTATTTCATCACAAATTCATCCCTCTCTCCTCTC TTCTCTCTCCCTCTCTCTCTCTTTCTCTTTGCTCATCATCTGTCATTTTGTCCGTTCCTCTCTCTGCGC CCTCAGCGTTCCCCACACTCTCTCGCTTCTCTTTTCCTAGACGTCTTCTTTTTTCATCTTCTTCAGCCT TTTTCGCCATTTTCCATCTCTGTCAATCATTACGGACGACCCCCATTATCGATAAGATCTCCACGGTG GCCGCGAATTCCTGCAGCCCGGGGGATCCCCGGGATTGGCCAAAGGACCCAAAGGTATGTTTCGAA TGATACTAACATAACATAGAACATTTTCAGGAGGACCCTTGGCTAGCGTCGACGGTACCGGGCCCCC CCTCGAGGTCGACGGTATCGATAACCTTCACAGCAGCGCACTCGGTGCCCCGCGCAGGGTCGCGA TG CTGCCCGGTT TGGCACTGTT CCTGCTGGCCGCCTGGACGG CTCGGGCGCT GGATGC AGAATTCCGA CATGACTCAG GATATGAAGT TCATCATCAAAAATTGGTGT TCTTTGCAGA AGATGTGGGT TCAAACAAAG GTGCAATCAT TGGACTCATGGTGGGCGGTG TTGTCATAGC GACAGTGATC GTCATCACCT TGGTGATGCT GAAGAAGAAACAGTACACAT CCATTCATCA TGGTGTGGTG GAGGTTGACG CCGCTGTCAC CCCAGAGGAGCGCCACCTGT CCAAGATGCA GCAGAACGGC TACGAAAATCCAACCTACAATTCTTTGAGCAGATGCAGAACTAGACCCCCGCCACAGCAGCCTCTGA AGTTGGACACGGATCCACTAGTTCTAGAGCGGCCGCCACCGCGGTGGAGCTCCGCATCGGCCGCT GTCATCAGATCGCCATCTCGCGCCCGTGCCTCTGACTTCTAAGTCCAATTACTCTTCAACATCCCTAC ATGCTCTTTCTCCCTGTGCTCCCACCCCCTATTTTTGTTATTATCAAAAAAACTTCTTCTTAATTTCTTT GTTTTTTAGCTTCTTTTAAGTCACCTCTAACAATGAAATTGTGTAGATTCAAAAATAGAATTAATTCGTA ATAAAAAGTCGAAAAAAATTGTGCTCCCTCCCCCCATTAATAATAATTCTATCCCAAAATCTACACAAT GTTCTGTGTACACTTCTTATGTTTTTTTTACTTCTGATAAATTTTTTTTGAAACATCATAGAAAAAACCG CACACAAAATACCTTATCATATGTTACGTTTCAGTTTATGACCGCAATTTTTATTTCTTCGCACGTCTG GGCCTCTCATGACGTCAAATCATGCTCATCGTGAAAAAGTTTTGGAGTATTTTTGGAATTTTTCAATCA AGTGAAAGTTTATGAAATTAATTTTCCTGCTTTTGCTTTTTGGGGGTTTCCCCTATTGTTTGTCAAGAG TTTCGAGGACGGCGTTTTTCTTGCTAAAATCACAAGTATTGATGAGCACGATGCAAGAAAGATCGGA AGAAGGTTTGGGTTTGAGGCTCAGTGGAAGGTGAGTAGAAGTTGATAATTTGAAAGTGGAGTAGTGT CTATGGGGTTTTTGCCTTAAATGACAGAATACATTCCCAATATACCAAACATAACTGTTTCCTACTAGT CGGCCGTACGGGCCCTTTCGTCTCGCGCGTTTCGGTGATGACGGTGAAAACCTCTGACACATGCAG CTCCCGGAGACGGTCACAGCTTGTCTGTAAGCGGATGCCGGGAGCAGACAAGCCCGTCAGGGCGC GTCAGCGGGTGTTGGCGGGTGTCGGGGCTGGCTTAACTATGCGGCATCAGAGCAGATTGTACTGAG AGTGCACCATATGCGGTGTGAAATACCGCACAGATGCGTAAGGAGAAAATACCGCATCAGGCGGCC TTAAGGGCCTCGTGATACGCCTATTTTTATAGGTTAATGTCATGATAATAATGGTTTCTTAGACGTCAG GTGGCACTTTTCGGGGAAATGTGCGCGGAACCCCTATTTGTTTATTTTTCTAAATACATTCAAATATGT ATCCGCTCATGAGACAATAACCCTGATAAATGCTTCAATAATATTGAAAAAGGAAGAGTATGAGTATT CAACATTTCCGTGTCGCCCTTATTCCCTTTTTTGCGGCATTTTGCCTTCCTGTTTTTGCTCACCCAGAA ACGCTGGTGAAAGTAAAAGATGCTGAAGATCAGTTGGGTGCACGAGTGGGTTACATCGAACTGGAT CTCAACAGCGGTAAGATCCTTGAGAGTTTTCGCCCCGAAGAACGTTTTCCAATGATGAGCACTTTTAA AGTTCTGCTATGTGGCGCGGTATTATCCCGTATTGACGCCGGGCAAGAGCAACTCGGTCGCCGCAT ACACTATTCTCAGAATGACTTGGTTGAGTACTCACCAGTCACAGAAAAGCATCTTACGGATGGCATGA CAGTAAGAGAATTATGCAGTGCTGCCATAACCATGAGTGATAACACTGCGGCCAACTTACTTCTGAC AACGATCGGAGGACCGAAGGAGCTAACCGCTTTTTTGCACAACATGGGGGATCATGTAACTCGCCTT GATCGTTGGGAACCGGAGCTGAATGAAGCCATACCAAACGACGAGCGTGACACCACGATGCCTGTA GCAATGGCAACAACGTTGCGCAAACTATTAACTGGCGAACTACTTACTCTAGCTTCCCGGCAACAAT TAATAGACTGGATGGAGGCGGATAAAGTTGCAGGACCACTTCTGCGCTCGGCCCTTCCGGCTGGCT GGTTTATTGCTGATAAATCTGGAGCCGGTGAGCGTGGGTCTCGCGGTATCATTGCAGCACTGGGGC CAGATGGTAAGCCCTCCCGTATCGTAGTTATCTACACGACGGGGAGTCAGGCAACTATGGATGAAC GAAATAGACAGATCGCTGAGATAGGTGCCTCACTGATTAAGCATTGGTAACTGTCAGACCAAGTTTA CTCATATATACTTTAGATTGATTTAAAACTTCATTTTTAATTTAAAAGGATCTAGGTGAAGATCCTTTTT GATAATCTCATGACCAAAATCCCTTAACGTGAGTTTTCGTTCCACTGAGCGTCAGACCCCGTAGAAAA GATCAAAGGATCTTCTTGAGATCCTTTTTTTCTGCGCGTAATCTGCTG CTTGCAAACAAAAAAACCACCGCTACCAGCGGTGGTTTGTTTGCCGGATCAAGAGCTACCAACTCTT TTTCCGAAGGTAACTGGCTTCAGCAGAGCGCAGATACCAAATACTGTCCTTCTAGTGTAGCCGTAGT TAGGCCACCACTTCAAGAACTCTGTAGCACCGCCTACATACCTCGCTCTGCTAATCCTGTTACCAGT GGCTGCTGCCAGTGGCGATAAGTCGTGTCTTACCGGGTTGGACTCAAGACGATAGTTACCGGATAA GGCGCAGCGGTCGGGCTGAACGGGGGGTTCGTGCACACAGCCCAGCTTGGAGCGAACGACCTACA CCGAACTGAGATACCTACAGCGTGAGCATTGAGAAAGCGCCACGCTTCCCGAAGGGAGAAAGGCG GACAGGTATCCGGTAAGCGGCAGGGTCGGAACAGGAGAGCGCACGAGGGAGCTTCCAGGGGGAA ACGCCTGGTATCTTTATAGTCCTGTCGGGTTTCGCCACCTCTGACTTGAGCGTCGATTTTTGTGATGC TCGTCAGGGGGGCGGAGCCTATGGAAAAACGCCAGCAACGCGGCCTTTTTACGGTTCCTGGCCTTT TGCTGGCCTTTTGCTCACATGTTCTTTCCTGCGTTATCCCCTGATTCTGTGGATAACCGTATTACCGC CTTTGAGTGAGCTGATACCGCTCGCCGCAGCCGAACGACCGAGCGCAGCGAGTCAGTGAGCGAGG AAGCGGAAGAGCGCCCAATACGCAAACCGCCTCTCCCCGCGCGTTGGCCGATTCATTAATGCAGCT GGCACGACAGGTTTCCCGACTGGAAAGCGGGCAGTGAGCGCAACGCAATTAATGTGAGTTAGCTCA CTCATTAGGCACCCCAGGCTTTACACTTTATGCTTCCGGCTCGTATGTTGTGTGGAATTGTGAGCGG ATAACAATTTCACACAGGAAACAGCT
References
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The present invention relates to a transgenic C. elegans which expresses an amyloid precursor protein (APP) or a part thereof, to the transgene itself, to the protein encoded by the transgene, and also to a process for preparing the transgenic C. elegans and to its use.
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This application is a continuation of application Ser. No. 701,340, filed Feb. 14, 1985, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to quick fastening devices for illumination apparatus, and in particular relates to electrical connection apparatus allowing an electrical connection to be made at variable positions along an insulated, flexible, electrical wire or conductor.
DESCRIPTION OF THE PRIOR ART
Prior art electrical connections of the type disclosed herein have been made for low voltage lighting primarily used as garden lights for a residence. In the traditional application a garden light is connected to an elongated type spike or rod which is placed in the ground along a walkway or other area desired to be illuminated. The garden light is electrically connected to an electrical source, usually in a nearby residence, by means of a flexible, insulated elongated conductor. Traditional lights of this nature have a plastic or metallic upper section of a "pagoda" type design surrounding a glass cover which houses the light bulb. The upper section connects to a lower section which houses the electrical components for the lamp. This lower section has a threaded opening through which project the electrical leads or conductors which provide the electrical connection to the lamp. A plastic socket mates with the threaded opening of the lower section and provides a means by which the conductors from the lamp may be connected with the flexible cable. The elongated spike is threaded into a base portion of the socket and provides the support for the entire lamp apparatus.
At the top of the spike where it is threaded to the metallic part of the lamp an electric cable is run through the spike such that it is substantially normal to the spike and lamp. The cable is run through a slot in the socket and when the spike is threaded onto the socket the force of the threading causes the conductors to pierce the insulation of the cable and make electrical contact with the lamp components. To move the lamp all that is generally required is to unscrew the spike from the socket thereby disconnecting the connectors from the electrical cable and sliding the lamp along the cable to a new position. The spike is then rethreaded into the socket portion of the lamp causing the connectors to pierce the insulation of the cable at the new location thereby making electrical contact. Since the garden lights are typically of a low voltage design, there is little or no risk of electrical shock or burn.
The socket portion into which the spike is threaded to compress the connectors against the cable has typically been of a single piece design having an inner threaded portion to receive the spike and an outer threaded portion to receive the threaded opening of the lower lampholder section. The electrical conductors from the lamp components project through the socket to the slot where they form a pair of sharpened points projecting into the cable receiving area of the socket. Thus, when the spike is threaded into the socket opening the cable is pressed against the sharpened contactors and the insulation is pierced. Since the socket is of a single piece design numerous manufacturing steps are required in its construction. The piece is normally of a plastic material and must be threaded on both the inside and outside areas, after the molding operation of the socket. A relatively complex mold is required to manufacture the one piece socket. These additional manufacturing steps increase the amount of time it takes to manufacture the socket and thus increase the expense of the part. Further, if the socket breaks in the field, the entire piece must be discarded for a new piece in order to operate the lamp. In the single piece design, the conductors must be fitted through the socket to the area where they will piece the electrical cable. This manner of assembly has developed an inefficient means for making the electrical connection as often the conductors are not firmly held in the socket. When the spike is threaded into the socket a poor connection is made.
Thus, there is a need in the field for a lamp socket to operate in connection with a low voltage outdoor lighting apparatus where the socket may be more economically and efficiently manufactured. Further, there is a need in the field for a socket to be used in connection with a low voltage lighting apparatus for outdoor use where the socket need not be discarded if a portion of it is broken or damaged. Also, there is a need in the field for a socket to be used in conjunction with a low voltage lighting apparatus that will provide a secure and efficient electrical contact between the conductors of the lamp and the flexible cable.
SUMMARY OF THE INVENTION
It is a general object of the present invention to provide a socket to be used in connection with a low voltage lighting apparatus for outdoor purposes where the socket will provide means for making an improved electrical connection with an energized elongated conductor at any point along its length. It is an additional object of the present invention to provide a socket for a low voltage lighting apparatus which requires a limited number of manufacturing steps for its manufacture. It is an additional object of the present invention to provide a low voltage lighting apparatus socket which will be easily replaceable in the field in the event of breakage or damage. It is an object of the present invention to provide a low voltage lighting apparatus socket which will provide means by which electrical contact with the electrical source can be easily and efficiently made.
The objects of the present invention are met by providing a socket assembly to be used in conjunction with a low voltage lighting apparatus for outdoor usage, connectable to an elongated support piece, also called a "spike". The objects of the present invention are satisfied by providing a plastic socket composed of three separate pieces each of which are made in a single molding operation. The socket is formed by combining two half sections together, each half section independently made in a separate mold. Each half section has molded therein inner threaded sections to receive the spike and an outer threaded portion to receive the threaded opening of the lower lampholder section. Each socket half has a pair of grooves therein to receive and restrain the lamp conductors. Each lamp conductor has sharpened, pointed ends to pierce the cable and a set of grooved portions to mate with the socket grooves. A retainer fits over the socket halves to maintain the socket halves together, and provides a means against which the spike will act to push the cable against the sharpened conductors. In this manner, when the spike is threaded into the socket the retaining member forces the cable against the sharpened conductors and makes electrical contact. When the lamp is desired to be removed, the spike is simply unscrewed allowing the cable to disengage from the sharpened conductors and allowing the lamp apparatus to be moved along the conductor to a new location.
It is felt that the above elements, as will be more fully described below, meet the objects of the invention indicated above and satisfy the needs that have developed in the usage of traditional socket arrangements for low voltage outdoor lights.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the present invention which are believed to be novel are set forth with particularity in the appended claims. The invention together with further objects and advantages thereof may best be understood by reference to the following description, taken in conjunction with the accompanying drawings in the several figures of which like reference numerals identify like elements, and in which:
FIG. 1 is a top perspective view of the lamp holder apparatus;
FIG. 2 is a side elevational view of the spike and socket portion of the lamp apparatus;
FIG. 3 is an exploded perspective view of the spike, socket, retaining member, and conductors for the lamp apparatus;
FIG. 4 is an exploded view of the assembled socket and retaining member and spike end;
FIG. 5 is a top perspective view showing in section the assembled socket having the conductors mounted therein;
FIG. 6 is a side elevational view of the assembled socket having the conductors mounted therein;
FIG. 7 is a bottom view of the assembled socket;
FIG. 8 is a top view of the assembled socket;
FIG. 9a is a front elevational view of a socket half;
FIG. 9b is a side elevational view of a socket half; and
FIG. 10 is a side elevational view of a lamp conductor.
DETAILED DESCRIPTION
Referring now to the drawings, FIG. 1 shows in perspective view the lamp 10 having spike 12 threaded thereon. Lamp 10 has metal lamp casing 14 which is threaded at socket area 16 onto spike 12. Spike 12 has pointed end 18 which is used to insert the lamp apparatus 10 into the ground to provide support therefore. Spike 12 is made of a rigid PVC plastic having point 18 glued or molded thereon as a separate piece.
FIG. 2 shows in side view the arrangement of spike 12 with socket area 16. It is seen that elongated cable 20 projects through socket area 16. It is in socket area 16 that the electrical connection is made with cable 20 for the lamp apparatus. Cable 20 carries the electrical power to the lamp apparatus 10. In its normal use, multiple lamp apparatuses will be placed along a single cable 20 such as where they are used to light a walkway to a residence. Socket area 16 has socket 22 threaded to spike 12. Retaining ring 24 is also mounted over spike 12 and interacts with socket 22 as will be explained in more detail below. FIG. 4 shows the relationship of spike 12, retaining ring 24, and socket 22. It should be noted that retaining ring 24 has unthreaded opening 26 and bar 28. Socket 22 has upper, outer threaded area 30 with conductor guide area 32 and opening 34. Also, socket 22 has slot 36 formed therein which receives bar 28 of retaining ring 24. Also, as can be noted in FIG. 4 the inner area of socket 22 has inner threaded portion 38 therein. Bar 28 fits within slot 36 of the socket. Bar 28 also provides a means by which the conductor 20 will be received through slot 36 and will have a portion against which the conductors will be compressed into cable 20 to make an electrical connection, as will be explained below. Spike 12 has upper threaded portion 40 which mates with the threaded section 38 of socket 22.
Conductor guide area 32, shown in FIG. 4 has opening 34 which provides a means by which the conductors which connect the electrical apparatus of the lamp 10 are transmitted to the inner portion of the socket 22 where they will mate with the cable 20. By screwing the upper threaded portion 40 of spike 12 into the inner threaded area 38 of socket 22 the retaining ring 24 is moved inwardly along slot 36 thus causing bar 28 to compress conductor 20 which is received within slot 36.
FIG. 5 shows socket 22 in a cut away view showing clearly the inner threaded opening 38 and a portion of the slot area 36. In FIG. 5 socket 22 is shown in an inverted position to better illustrate the conductor tips 42 which project through openings 44 in socket 22. These conductor tips 42 provide the means by which the outer insulated area of cable 20 is pierced to make electrical connection with the lamp elements. Conductor tips 42 are electrically connected to the lamp elements through conductor guide area 32 which is received into the metal casing area 14 of lamp 10. Line 46 designates the split section of socket 22 which is shown in more detail in FIG. 3.
Referring now to FIG. 3 it is seen that the socket 22 is comprised of two half sections 22a and 22b. By forming socket 22 into two half sections 22a and 22b, the entire socket half section may be made in a single molding step. Individual molds are required for each section 22a and 22b, however, the threads for the inner threaded portion 38 and the outer threaded area 30 may be formed in the mold rather than by a cutting process which is an additional step.
Guide slots 52 are also molded on the inner side of socket 22a and socket 22b. These guide slots receive leads 50 which contain at their outer ends the conductor tips 42. The conductors 48 are connected at the other end of leads 50 which connect to the electrical elements of the light fixture in the lamp apparatus 10. Projection 54 is molded in socket 22b as shown in FIG. 3 with a corresponding projection 54 molded in socket 22a. Opening 56 is also molded as shown in socket 22b with a corresponding opening 56 molded in socket 22a. When mated, socket halves 22a and 22b are joined by having projections 54 mate with openings 56. This helps hold the socket halves 22a and 22b together to form the single socket 22. Additionally, retaining ring 24 is slipped over the mated socket halves 22a and 22b to hold the socket halves in place. As stated before, retaining ring 24 slips over socket 22 such that bar 28 is received in slot 36 of socket 22. When upper threaded portion 40 of spike 12 is threaded into the mated socket 20, the combination of the retaining ring 24 and the threading of upper end 40 into inner threaded portion 38 of socket 22 secure the assembly together.
FIG. 10 illustrates in greater detail the leads 50. As stated previously, leads 50 have conductor tips 42 projecting therefrom. Also, leads 50 have projections 58 on each side thereof approximately midway between the opposing ends of leads 50. Projections 60 are shown at the end opposite the end containing the conductor tips 42. FIGS. 9a and 9b show a side and section view of socket half 22a. Socket half 22b is shown in detail in FIG. 3 and is identical to socket half 22a shown in FIG. 9a with the exception that projection 54 and opening 56 are reversed on socket 22b to provide the means by which the projections 54 will mate with openings 56 when socket halves 22a and 22b are joined together. Lead slots 52 are shown in FIG. 9a having a reduced or an increased depth section 62. This increased depth section 62 receives the projections 58 on leads 50 when the leads 50 are inserted in lead slots 52. The projections 58 and increased depth sections 62 interact to provide a means by which the leads 50 will be firmly mounted in the lead slots 52 allowing the conductor tips 42 to project into the cable 20. The projection of the conductor tips 42 is shown again in FIG. 5 when the socket assembly is assembled. Projections 60 of leads 50 fit in lead slots 52 at end 64 where an increased depth section is provided for projections 60. The conductors 38 shown in FIG. 3 when mounted in lead slots 52 as described above would project through conductor guide area 32 to be connected with the lamp elements. FIG. 9b shows in section view the detail of lead slots 52. Again, the increased depth section 62 is shown in lead slot 52 in FIG. 9b. Area 64 along lead slot 52 receives the projection 60 of the lead 50. These increased depth sections 62 and 64 act to maintain the lead 50 in the desired location within socket 22. Both sockets 22a and 22b have a similar configuration for lead slots 52. Thus, both act to hold the lead 50 in place when the sockets are mated.
FIG. 7 shows the mated socket 22 and the conductor tip openings 44. It is seen that these openings are each formed by a half section of the socket and by the joining of the sockets together.
FIG. 8 illustrates a top view of socket 22 showing the lead slots 52 formed by the mating of socket halves 22a and 22b.
When assembled, the conductor 20 is slipped through the slot 36 in socket 22 and the spike 12 has threaded upper end 40 threaded into inner threaded portion 38 of the socket 22. This forces the retaining ring 24 against the cable 20's insulation against the conductor tips 42. Once the insulation of conductor 20 is pierced by conductor tips 42 an electrical contact is made to the lamp elements. The spike 12 is continued to be threaded into the inner threaded portion 38 of socket 22 until a secure and firm connection, both mechanically and electrically, is formed. The lamp apparatus 10 is retained in this position for as long as its use is desired. When a movement of the lamp apparatus with respect to the cable 20 is desired, the spike 12 is removed from the ground and the upper threaded portion 40 is unthreaded with respect to the inner threaded portion 38. This removes the pressure from the cable 20 and allows cable 20 to be removed from the conductor tips 42 such that the entire lamp apparatus may be removed with respect to cable 20 to a new location. At the new location the spike 12 is again tightened into inner threaded opening 38 until the conductor tips pierce the cable 20 insulation and provide a new electrical connection. In view of the low voltage rating of the lamp apparatus, the previous puncture marks made by the conductor tips 42 do not cause a shock or burn hazard.
The above invention provides a unique and efficient means of manufacturing a socket 22 to be used in connection with an outdoor lamp apparatus. In a single molding step the socket is formed. This socket not only provides a reduced cost to manufacture, but also provides a means by which an increased and better mechanical and electrical connection is made between the conductor tips and the electrical cable 20.
The invention described above is not limited to the particular details of construction of the device depicted, and other modifications and applications may be made. For example, a different shape may be used for the leads 50 and the projections 58 and 60 such that a firm and secure mechanical and electrical connection may still be maintained in the slots 52. Also, the slots 36 in socket 22 may be arranged at a location other than that shown with respect to section line 46. Certain other changes may be made in the above described device without departing from the true spirit and scope of the invention herein involved. It is intended therefore that the subject matter of the above description shall be interpreted as illustrative and not in a limiting sense.
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A connector for multiconductor wire comprising a longitudinally divided socket having external threaded segments on one end of respective socket portions, and internally threaded segments on opposite ends of the socket portions. An externally threaded support element mates with the socket internal thread segments thereby applying pressure to a ring disposed between the support element and conductors disposed in a cable receiving area in alignment therewith. Contacts are immovably held between mating faces of the socket portions, and contain contacting portions extending into the conductor-receiving area thereby allowing electrical connection of the conductors and contacting portions upon mating of the support element and internal socket threads.
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CLAIM OF PRIORITY
[0001] This application claims the benefit of U.S. Provisional Application No. 62/079,351, filed Nov. 13, 2014,
TECHNICAL FIELD
[0002] The present disclosure relates generally to systems and method for temporarily or permanently joining two surfaces. More specifically, the present disclosure relates to systems and methods for temporarily or permanently joining two surfaces using a releasable adhesive.
BACKGROUND
[0003] Reversible joining processes can be used to temporarily join materials or components. Suction connections are commonly used to join surfaces temporarily in material handling through the use of manual or vacuum-operated suction.
[0004] Although suction connections are reversible in nature, the bond formed can be weakened by impurities on any of the relevant surfaces, which can lead to diminished bonding in the suction-based connection. For example, oil or dirt on a surface of a part being joined, to a suction cup, can substantially weaken the bond formed at the joining surfaces. Diminished bonding can be of particular issue where the part being joined is subjected to high-speed attachment to the suction connection.
[0005] Additionally, some suction connections require a constant vacuum connection to maintain the temporary bond, especially where the part being joined includes surface texture or a complex geometry. However, the suction connection that uses a constant vacuum may prematurely disconnect from the part being joined in the event of a power failure, for example of the vacuum.
SUMMARY
[0006] A need exists for a suction system reversible in nature, or releasable, after installation. The suction system adhesive would have load-carrying capabilities when attached to a surface, and be able to release quickly to disjoin from the surface upon a pre-determined amount of peel force.
[0007] The present technology relates to systems including a releasable adhesive having many applications including in commercial industry, the private-sector (e.g., consumer), and manufacturing, among others. The releasable adhesive forms a reversible bond that utilizes van der Waals force to adhere to a surface.
[0008] The releasable adhesive releasable adhesive comprises a primary material having a first portion including at least one first-portion molecule that is configured to be positioned parallel with at least one molecule of the attaching surface, and a second portion, opposite the first portion, that is configured to permanently attach to an interior surface of the suction device. The at least one first-portion molecule positioned parallel with the molecule of the attaching surface is configured to (a) maintain a bond between the first portion and the attaching surface up to a pre-determined shear force being exerted on the attaching surface, (b) maintain a bond between the first portion and the attaching surface up to a pull force of a pre-determined amount being exerted on the attaching surface, and/or (c) release the bond between the first portion and the first, attaching surface in response to a peel force exerted on the attaching surface above a pre-determined amount. In some embodiments, a plurality of first-molecules contact a plurality of molecules in the attaching surface during operation of the releasable adhesive system (e.g., when the suction device is engaged).
[0009] In some embodiments, the primary material is shaped into a plurality of components each having the first portion configured to be positioned parallel with at least one molecule of the attaching surface and the second portion configured to permanently attach to the suction device. In some embodiments, each of the plurality of components is positioned at a location and extend in a direction outward from the location, forming a plurality of radii from the location. Each of the plurality of radii may be positioned at an angle with a preceding radius and a succeeding radius. In some embodiments the plurality of components are shaped to allow concentric positioning of each of the plurality of components with respect to one another.
[0010] Also provided is method for using the suction device on the attaching surface, wherein the suction device contains the releasable adhesive. The method comprises positioning the suction device approximately near an attaching surface engaging the first portion with the attaching surface using a securing device, wherein at least a portion of the suction device is approximately flat against the attaching surface.
[0011] In some embodiments, the engaging occurs by at least temporarily attaching a securing device to an exterior surface of the suction device. Air between the interior surface of the suction device and the attaching surface can be at least partially removed using the securing device. The securing device may be a vacuum.
[0012] In some embodiments, the method further comprises, releasing the bond between the first portion and the attaching surface using the peel force. In some embodiments, the releasing occurs by introducing air into the inner surface of the suction device. Releasing can occur by exerting a force eon a securing device in contact with the attaching surface such that the suction device is released from the attaching surface. The securing device may be compressed air provided by a vacuum line.
[0013] Other aspects of the present technology are described hereinafter.
DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 illustrates a side view of a removable adhesive in accordance with an embodiment of the present technology.
[0015] FIG. 2 is a perspective view of an alternative embodiment of the removable adhesive of
[0016] FIG. 1 .
[0017] FIG. 3 is a side view of a second alternative embodiment of the removable adhesive of FIG. 1 .
[0018] FIG. 4 is a perspective view of a third alternative embodiment of the removable adhesive of FIG. 1 .
[0019] FIG. 5 illustrates a perspective view of a suction application of the removable adhesive of FIG. 1 .
[0020] FIG. 6 illustrates a process for using the releasable adhesive in the suction application of FIG. 5 .
[0021] FIG. 7 illustrates at top view of patterns of the releasable adhesive used by the suction application of FIG. 5 .
[0022] The figures are not necessarily to scale and some features may be exaggerated or minimized, such as to show details of particular components. In some instances, well-known components, systems, materials or methods have not been described in detail in order to avoid obscuring the present disclosure. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present disclosure.
DETAILED DESCRIPTION
[0023] As required, detailed embodiments of the present disclosure are disclosed herein. The disclosed embodiments are merely examples that may be embodied in various and alternative forms, and combinations thereof. As used herein, for example, exemplary, and similar terms, refer expansively to embodiments that serve as an illustration, specimen, model or pattern.
[0024] While the present technology is described primarily herein in connection with automobiles, the technology is not limited to automobiles. The concepts can be used in a wide variety of vehicle applications, such as in connection with aircraft, marine craft, and other vehicles, and consumer electronic components. Additionally, the concepts can be used in a variety of consumer applications, such as electronic components, clothing design (e.g., fasteners and closures), apparel gripping (e.g., work gloves and sports gloves), and signs (e.g., permanent signage for a business and temporary signage for a traffic detour), among others. Furthermore, the concepts can be used in low temperature environments (e.g., aeronautical applications in space) where conventional adhesives lose gripping.
[0025] Various embodiments of the present disclosure are disclosed herein. The disclosed embodiments are merely examples that may be embodied in various and alternative forms, and combinations thereof.
I. Overview of the Disclosure
[0026] FIG. 1 illustrates a releasable adhesive 100 , which allows reversible bonding through the use of van der Waals force. The releasable adhesive 100 adheres and releases from a first surface 10 and a second surface 20 where surface 10 , 20 are substantially solid surfaces made of varying materials and textures of the surfaces 10 , 20 .
[0027] The releasable adhesive 100 comprises a primary material 110 that has particles (e.g., molecules, atoms, ions) generally parallel with respect to particles within the first surface 10 , the second surface 20 . As seen in the callout of FIG. 1 , molecules 115 of the primary material 110 are parallel with molecules 25 of the second surface 20 , at a location of attachment. Van der Waals force allows the molecules 115 of the primary material 110 to adhere to the second surface 20 . Specifically, the molecules 115 of the primary material 110 maintain a bond between the releasable adhesive 100 and an attaching surface (e.g., the second surface 20 ) against pull forces 80 and shear forces 85 .
[0028] Unlike a traditional chemical bonding process required by typical adhesives, the releasable adhesive 100 does not require curing, thus allowing the releasable adhesive 100 to adhere to the surfaces 10 , 20 almost instantaneously. The releasable adhesive 100 can also adhere to the surface 10 , 20 without use of an external power supply, actuator, or otherwise.
[0029] Van der Waals force also allows the bond between the molecules 115 of the primary material 110 and the molecules of the attaching surface (e.g., the molecules 25 of the second surface 20 ) to detach when peel forces 90 are applied to the surfaces attaching surface or the releasable adhesive 100 . As seen in the callout of FIG. 1 , where the primary material 110 is not in contact with to the second surface 20 , the molecules 115 of the primary material 110 are not generally parallel to the molecules 25 of the second surface 20 .
[0030] In some embodiments, the primary material 110 includes a microstructured and/or a nanostructured polymer, such as silicone and polydimethylsiloxane (PDMS), among others. In some embodiments, the primary material 110 includes polymers such as (functionalized) polycarbonate, polyolefin (e.g., polyethylene and polypropylene), polyamide (e.g., nylons), polyacrylate, acrylonitrile butadiene styrene.
[0031] In some embodiments, the primary material 110 includes composites such as reinforced plastics where the plastics may include any of the exemplary polymers listed above, and the reinforcement may include one or more of the following: clay, glass, carbon, polymer in the form of particulate, fibers (e.g., nano, short, or long fibers), platelets (e.g., nano-sized or micron-sized platelets), and whiskers, among others.
[0032] The primary material 110 can include synthetic or inorganic, molecules. While use of so-called biopolymers (or, green polymers) is becoming popular in many industries, petroleum based polymers are still much more common in every-day use. The primary material 110 may also include recycled material, such as a polybutylene terephthalate (PBT) polymer, being, e.g., about eighty-five percent post-consumer polyethylene terephthalate (PET). In one embodiment, the primary material 110 includes some sort of plastic. In one embodiment, the material includes a thermoplastic.
[0033] In one embodiment the primary material 110 includes a composite. For example, the primary material 110 can include a fiber-reinforced polymer (FRP) composite, such as a carbon-fiber-reinforced polymer (CFRP), or a glass-fiber-reinforced polymer (GFRP). The composite may be a fiberglass composite, for instance. In one embodiment, the FRP composite is a hybrid plastic-metal composite (e.g., plastic composite containing metal reinforcing fibers). The primary material 110 in some implementations includes a polyamide-grade polymer, which can be referred to generally as a polyamide. In one embodiment, the primary material 110 includes acrylonitrile-butadiene-styrene (ABS). In one embodiment, the primary material 110 includes a polycarbonate (PC). The primary material 110 may also comprise a type of resin. Example resins include a fiberglass reinforced polypropylene (PP) resin, a PC/PBT resin, and a PC/ABS resin.
II. Embodiments of the Releasable Adhesive
[0034] In the embodiment shown in FIG. 1 , the releasable adhesive 100 comprises a plurality of setae 130 (e.g., synthetic setae). Van der Waals force allows the primary material 110 within/on each setae 130 to adhere and release to the surfaces 10 , 20 using attractions and repulsions between particles (e.g., atoms, molecules, ions) of the primary material 110 and the surfaces 10 , 20 .
[0035] As described above, van der Waals force allows the molecules 115 of the primary material 110 to attach and detach from the molecules of the attaching surface (e.g., the molecules 25 of the second surface 20 ), depending on the orientation of the molecules 115 of the primary material 110 and the molecules of the attaching surface. Specifically, the van der Waals force allows the primary material 110 within or on the setae 130 to attach to and peel away from the surfaces 10 , 20 to reverse (release) the bond formed between the primary material 110 within/on the setae 130 and the surfaces 10 , 20 .
[0036] Impurities on or in the surfaces 10 , 20 , such as dirt, oil, and air pockets, do not substantially weaken the overall bond formed by the releasable adhesive 100 because of the many areas of contact between the setae 130 and the surface 10 , 20 . Specifically, the setae 130 form a plurality of independent bonds with the surface 10 , 20 , which allows the releasable adhesive 100 to bond even with the existence of some impurities affecting the bond at one or more limited points of interface.
[0037] The releasable adhesive 100 , including each setae 130 , may be designed to have a pre-determined of load-bearing capability. For example, where a load to be bore is from a small object under tension loading, the load bearing capability of the releasable adhesive 100 may be between about 0.05 kilograms of force per square centimeter (kg/cm 2 ) and about 1.0 kg/cm 2 , wherein the area measurement (cm 2 ) is the surface area of the primary material 110 within/on each setae 130 . However, where the object is under shear loading, the load bearing capability of the releasable adhesive 100 may be between about 1.0 and about 20 kg/cm 2 .
[0038] In some embodiments, as also shown in FIG. 1 , the primary material 110 is infused with an embedded material 120 . In some embodiments, the embedded material 120 is a material being similar in composition (e.g., material composition or chemical composition) to the primary material 110 . In other embodiments, the embedded material 120 is a material different than the primary material 110 .
[0039] The embedded material 120 can include particles or pathways infused into a molecular structure of the primary material 110 . The embedded material 120 may be infused into each of the setae 130 within the primary material 110 . Alternatively, the embedded material 120 may be infused into selected setae 130 , shown in FIG. 1 .
[0040] In some embodiments, the embedded material 120 is selected to reinforce strength of the primary material. Reinforcing strength of the primary material allows the primary material to sustain against greater shear forces and pull forces.
[0041] In some embodiments, the embedded material 120 may be used to increase electrical and/or thermal conductivity of the primary material 110 . For example, doping (e.g., vary placement any numbering of electrons and holes within a molecular structure) can be used to increase conductivity of the primary material 110 . Increasing conductivity of the primary material, and thus releasable adhesive 100 , may be important in applications where the surfaces 10 , 20 need to conduct electricity. For example, doping of the primary material 110 may be suitable in an application where the releasable adhesive 100 serves as a conductor within a battery application.
[0042] The embedded material 120 can include a conductive fillers such as, but not limited to, carbon nanotubes, carbon black, metal nanoparticles (e.g., copper, silver, and gold), or combination thereof.
[0043] In another embodiment, seen in FIG. 2 , the setae 130 are formed into an array of truncated prisms 132 . Each truncated prism includes at least one side 134 and at top 136 (seen in the callout of FIG. 1 ), which serve as flat, generally flat, or smooth surfaces to maximize contact with an attaching surface (e.g., the first surface 10 ). The van der Waals force that can be exerted on the attaching surface is higher with greater contact area, and so maximizing contact with the attaching surface is a priority in design of the adhesive 100 .
[0044] In some embodiments the truncated prisms can vary in geometric shape. For example, as seen in FIG. 2 , the array of truncated prisms can be formed in the shape of a truncated pyramid, where each pyramid includes two sides 134 and top 136 that are used to generate sufficient van der Waals force for adhesion with the surfaces 10 , 20 . However, the array of truncated prisms can be in the form of a truncated cone (e.g., sloping or frustro-conical surface), where the side 134 extends around a circumference of a circular base.
[0045] Impurities on or in the surfaces 10 , 20 , such as dirt, oil, and air pockets, do not lead to a substantial weaken the overall bond because of the many areas of contact between the truncated prisms 132 and the surface 10 , 20 . Specifically, the truncated prisms 132 form a plurality of independent bonds with the surface 10 , 20 , which allows the releasable adhesive 100 to bond even with the existence of some impurities affecting the bond at one or more limited points of interface.
[0046] The array of truncated prisms 132 are extended across a defined width 140 . The width 140 can range approximately between 1 millimeter (mm) and 20 mm. The truncated prisms repeat along a defined length 142 with a range similar to the width 140 . Spacing between each prism 132 should be sufficient to allow contact to a surface (e.g., the first surface 10 ). For example, a space 138 between one edges of a first prism 132 and a subsequent prism 132 may be between 10 nanometers (nm) and 200 micrometers (μm—).
[0047] In some embodiments, the truncated prisms 132 may include the embedded material 120 . The embedded material 120 may be added (e.g., doped) into the microstructure of truncated prisms 132 .
[0048] In another embodiment, seen in FIG. 3 the releasable adhesive 100 may include a plurality of layers including an adhesion pad 150 , a skin 160 , and a tendon 170 . Collectively, the plurality of layers maximize areas of contact with the surfaces 10 , 20 while maintaining stiffness a direction of applied loads (e.g., along the fibers of the fabric of the skin 160 ).
[0049] In this embodiment, the adhesion pad 150 (e.g., a polymer elastomer) attaches to the skin 160 (e.g., woven fabric) which is attached to a tendon (e.g., woven fabric). Attaching the adhesion pad 150 to the skin 160 and the tendon 170 provides strength enabling adhesion to maintain against shear force 85 and pull force 80 . An example in FIG. 3 illustrates how the first surface 10 is maintained against shear forces 85 and pull forces 80 through stiffness of fabric (e.g., fibers) within the releasable adhesive 100 .
[0050] Additionally, the plurality of layers provide stiffness in a direction of peel loading (e.g., peel force 90 ), thus enabling release from the attached surface (e.g., the second surface 20 as seen in FIG. 3 ).
[0051] The adhesion pad 150 may include materials that behave elastically within a pre-determined force capacity range of a desired application. The materials should ensure deformation losses (e.g., viscoelastie, plastic, or fracture) in the materials of the adhesion pad 150 are minimized or otherwise reduced. The adhesion pad 150 may include materials such as, but not limited to, silicone, PDMS, and the like. The adhesion pad 150 may have a thickness between 10 nm and 100 nm.
[0052] The skin 160 may include similar elastic materials that minimize deformation losses as described in association with the adhesion pad 150 . The skin 160 may include woven fabric materials such as carbon fiber fabric, fiber glass, KEVLAR® (KEVLAR is a registered trademark of E. I. du Pont de Nemours and Company of Wilmington, Del.), and the like. The skin 160 may have a thickness between 10 nm and 1 mm.
[0053] The tendon 170 may include woven fabric materials with high stiffness fibers such as glass fiber, nylon, and carbon-fiber, among others. The tendon 170 should be of a thickness that sufficient attaches the pad 150 to the skin 160 . For example, the tendon 170 can have a length between 1 mm and 100 mm.
[0054] The connection between the tendon 170 and the adhesion pad 150 may have pre-defined dimensions, orientation, and spatial location according to particular a desired application. The pre-defined dimension can be altered to balance shear and normal loading requirements for the desired application.
[0055] In electrically conductive applications, the pad 150 can be doped with the embedded material 120 . For example, the embedded material 120 can include metal nanoparticles as stated above. In some embodiments, the skin 160 and/or the tendon 170 can also be doped electrically conductive materials (e.g., carbon fiber fabric).
[0056] Where the tendon 170 attaches to the pad 150 can affect functionality of the releasable adhesive 100 . Characteristics such as thickness of the tendon 170 , material composition of the tendon 170 , and positioning of tendon 170 with respect to the pad 150 can be set in various ways to achieve different results for desired performance in various applications. For example, positioning of the tendon 170 can affecting hanging ability. Attaching the tendon 170 at an edge of pad 150 allows increase strength of the releasable adhesive 100 in the shear direction, as seen in FIG. 3 . However, attaching the tendon 170 on an inner surface of the pad 150 allows increased strength of the releasable adhesive 100 in the pull direction.
[0057] In another embodiment, seen in FIG. 4 the releasable adhesive 100 (e.g., setae 130 , the prisms 132 ) may be formed as a flexible structure that can be molded to surround or otherwise connect surfaces. For example, the releasable adhesive 100 may function similar to single-sided tape.
[0058] In some embodiments, the releasable adhesive 100 can be included on one more than one surface for purposes of adhesion. For example, the releasable adhesive 100 may function as a double-sided tape.
[0059] The single-sided or double-sided tape may be used to position between, pinch together, wrap around, or otherwise hold together the surfaces 10 , 20 .
[0060] The single-sided or double-sided tape may utilize the releasable adhesive 100 in a non-conductive form or with conductive doping, using the embedded material 120 . For example, the releasable adhesive 100 may be in the form of a conductive, single-sided tape, which may be used to secure the surfaces 10 , 20 to one another and pass electrical currents through one another and the single-sided tape, as seen in FIG. 4 .
III. Releasable Adhesive Application
[0061] FIG. 5 illustrates use of the releasable adhesive 100 in a suction-connection application. A single-sided form of the releasable adhesive 100 may be used to bond a suction cup 200 to a surface using a securing device 210 . In suction applications, the first surface 10 is an inside surface of the suction cup 200 affixed to (e.g., using a conventional permanent adhesive) a non-adhesive side of the releasable adhesive 100 , and the second surface 20 is a contact surface of an item to which the suction cup 200 is to attach, as seen in FIG. 5 .
[0062] The releasable adhesive 100 within suction applications should be of a thickness to allow contact with the inside surface of the suction cup 200 . Additionally, the thickness of the releasable adhesive 100 should be such that the suction cup 200 may significantly flatten during engagement with the second surface 20 . For example, the thickness of the releasable adhesive 100 may be between about 100 μm and about 2.0 mm to prevent introduction of air into the suction cup 200 , which may diminish the holding of the suction cup 200 .
[0063] FIG. 6 illustrates a process for positioning, engaging, and releasing the suction cup 200 , including the releasable adhesive 100 , from the second surface 20 .
[0064] At step 230 , the suction cup 200 is positioned approximately near the second surface 20 . During positioning, the suction cup 200 is placed with the releasable adhesive 100 adjacent the second surface 20 (e.g., the suction cup 200 facing down). The securing device 210 can be used to push the suction cup 200 to the second surface 20 or stabilize the suction cup 200 while the second surface 20 is pushed to the suction cup 200 . For example, the securing device 210 can be a mechanical device to push the suction cup 200 to the second surface 20 . Alternatively, the securing device 210 can be a vacuum line used to remove air between the inside surface of the suction cup 200 and the second surface 20 , thus securing the suction cup 200 to the second surface 20 .
[0065] At step 240 , the suction cup 200 is fully engaged with the second surface 20 (e.g., at least a portion of the suction cup 200 is flat against the second surface 20 ). During engagement, the inside surface of the suction cup 200 , which contains the releasable adhesive 100 , is fully engaged or otherwise connected to the second surface 20 . In some embodiments, the suction cup 200 may be held in connection with the second surface 20 by a device to enhance holding of the suction cup 200 (e.g., vacuum).
[0066] Utilizing the releasable adhesive 100 with the suction cup 200 , may enhance holding power of vacuum grippers, for example, when the second surface 20 is subjected to high-speed attachment and placement. Specifically, the releasable adhesive 100 can hold the second surface 20 without vacuum and its restrictions to certain surface texture or geometry conditions. In some circumstances, the gripper may also be used as fail-safe in the event of power or vacuum source failure.
[0067] At step 250 , the suction cup 200 is released from the second surface 20 . The suction cup 200 can be released by using the securing device 210 as a push plunger, for example, to peel the suction cup 200 from the second surface 20 . Alternatively, compressed air can be introduced into the inside surface of the suction cup 200 using the securing device 210 . When the suction cup 200 is released, the releasable adhesive 100 is separated from the second surface 20 .
[0068] Additionally, the releasable adhesive 100 may form patterns within the suction cup 200 as seen in FIG. 7 . Patterns accommodate general properties (e.g., geometry and texture) and functional properties (e.g., load capacity) of the suction cup 200 . Additionally, patterns may increase the holding force in the lateral and/or shear direction, providing resistance to the attaching surface (e.g., the second surface 20 ). Patterns may include, but are not limited to, a fill cup pattern 262 , a radial pattern 264 , a ring pattern 266 , and a grid pattern 268 . One of skill in the art would anticipate other patterns are possible depending on the application.
[0069] The full cup pattern 262 may be beneficial where maximum contact of the releasable adhesive 100 is desired to the surface 20 . Creating maximum contact may be needed where the releasable adhesive 100 is intended to carry a load near a maximum material constraint of the releasable adhesive 100 .
[0070] The radial pattern 264 may be beneficial where the first surface 10 inside the suction cup 200 may include radial ribs that increase the stiffness of the suction cup 200 . The radial pattern 264 is an effective way to attach the releasable adhesive 100 to the suction cup 200 and enhance its holding or bonding capability. The radial pattern 264 may also provide for a faster release of the suction cup 200 as compared to the frill cup pattern 262 , for example, due to less of the releasable adhesive 100 being employed.
[0071] An angle 265 can be formed between each of the radii to adequately space the releasable adhesive 100 throughout the suction cup 200 . The angle 265 can be the same throughout the radial pattern 264 , as seen in FIG. 7 . Alternatively, the angle 265 can vary throughout the radial pattern 264 .
[0072] The ring pattern 266 may also be beneficial where the first surface 10 inside the suction cup 200 has a non-conical geometry (e.g., spherical) that requires a plurality of releasable adhesives 100 (e.g., in the form of narrow rings) to simplify attachment to the suction cup 200 and maintain the maximum contact with the first surface 10 . The number of rings can depend on factors such as the amount of release time. For example, the fewer the amount of rings, the faster the suction cup 200 can be released.
[0073] Geometric shapes forming the ring pattern 266 can be concentric in nature as seen in FIG. 6 where the concentric geometric shape of the ring pattern 266 is circular. It should be appreciated that the ring pattern 266 can be formed using a number of geometric shapes such as squares, circles, ovals, and triangles, among others.
[0074] The grid pattern 268 may be beneficial where a pre-determined surface area of the suction cup 200 needs to be covered, but where the full cup pattern 262 is not necessary. The grid pattern 26 g can provide for quick attachement of the releasable adhesive 100 to the first surface 10 of the suction cup 200 . The grid pattern 268 can be formed using a number of geometric shapes desirable for particular applications such as circles, squares, ovals, and the like. The geometric shaped forming the grid pattern can be independent in nature as seen by as seen in FIG. 6 where the geometric shape of the grid pattern 268 is a square.
[0075] In some embodiments, the releasable adhesive 100 may include a plurality of conductive suction cups 200 on an electrically conductive substrate (e.g., metal or conductive polymer). In such an application, the primary material 110 used within the suction cups 200 can include one or more electrically conductive materials as described above.
IV. CONCLUSION
[0076] Various embodiments of the present disclosure are disclosed herein. The disclosed embodiments are merely examples that may be embodied in various and alternative forms, and combinations thereof.
[0077] The above-described embodiments are merely exemplary illustrations of implementations set forth for a clear understanding of the principles of the disclosure.
[0078] Variations, modifications, and combinations may be made to the above-described embodiments without departing from the scope of the claims. All such variations, modifications, and combinations are included herein by the scope of this disclosure and the following claims.
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A releasable adhesive system, for securing a suction device to an attaching surface. The releasable adhesive comprises a primary material having a first portion including at least one first-portion molecule that is configured to be positioned parallel with at least one molecule of the attaching surface, and a second portion, opposite the first portion, that is configured to permanently attach to an interior surface of the suction device. The first-portion molecule positioned parallel with the molecule of the attaching surface is configured to maintain a bond between the first portion and the attaching surface up to one or more pre-determined forces on the attaching surface, such as a pre-determined shear force, pull force, and peel force. Also provided is method for using the suction device on the attaching surface, wherein the suction device contains the releasable adhesive.
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TECHNICAL FIELD
The present invention relates generally to the production of articles using superplastic forming. More particularly, the present invention relates to a method and apparatus utilizing a first step in which a pre-form is created with a die and punch and a second step in which the pre-form is subjected to gas pressure in a forming cavity to complete formation of the part. A metallic gasket is provided to ensure that no pressurized gas escapes from the forming cavity.
BACKGROUND OF THE INVENTION
The use of aluminum components in motor vehicles continues to expand due to the relatively good strength-to-weight ratio of this material. However, the expanded application of components made from this material is being hampered because of its limited temperature formability. One increasingly popular method of producing components from aluminum is superplastic forming in which certain materials, including particularly aluminum, are heated (under controlled temperature) and stretched slowly (under a controlled strain rate) to achieve dimensions that are well beyond their normal limitations. Superplastic forming offers a variety of advantages over conventional stamping techniques. Some of these advantages include increased forming strains, zero springback, and very low tooling costs. These alloys can be formed with relatively low forces and they permit a high level of detail in the design of the formed part.
Superplastic forming can result in very deep components which would rupture during the formation process by using conventional methods. The large degree of plastic strain that can be achieved with this process (>200%) makes it possible to form complex parts that cannot be shaped with conventional stamping techniques. As a result, the components produced by superplastic forming processes can embody relatively complex and highly integrated configurations. These components are not only lightweight but also exhibit a high degree of integrity, eliminating not only the number of parts and connectors, but also reducing the number of assembly operations because of the complexities that can be achieved.
Typical superplastic forming takes place in a simple one-sided, single action tool. The blank is clamped in a heated die and then blow formed with gas pressure into a female die. The part detail is captured within a single die rather than a matched pair and therefore tooling is significantly less expensive than that of conventional stamping. Furthermore, the low forces needed to form the material at these elevated temperatures allows for the use of cast iron dies instead of the harder to work and more expensive tool steel.
While superplastic forming may be a viable manufacturing option for some parts, there are limitations in the economic feasibility of this technique. Superplastic response in metals is inherently coupled with the rate of deformation and there exists only a narrow range of strain rates, typically slow strain rates, in which these materials display superplastic response. This results in a relatively slow cycle time which often leaves superplastic forming as a cost-prohibitive option for parts having volumes greater than 1000 parts per year.
Another problem related to SPF stems from the inability to draw material into the die cavity. Although the superplastic material utilized in SPF can undergo substantial deformation, its formability is limited to the amount of material in the die. After the die faces are clamped and sealed, additional material cannot be drawn into the die. This may result in tears or inconsistent wall thickness in the part being formed. To overcome this, U.S. Pat. No. 5,974,847 introduces pre-forming the material around a punch before sealing the dies and completing the forming process by gas pressure injection. This approach reduces the amount of superplastic forming that takes place thereby reducing the cycle time and potentially allowing greater design freedom due to the additional material drawn into the die during the pre-forming step. While the method of this patent teaches pre-forming the material before the gas is injected, the method does not restrain the material entering the die during the pre-forming step. Without a restraining force on the material, such as blankholder force, the material will wrinkle around the punch in all but the simplest of formings. Wrinkling of the material during pre-forming will result in either the inability to complete the part during subsequent gas pressure forming or, at best, a low quality finished part.
In response to the need to reduce the problem of excessive wrinkling of the material during the pre-forming step, U.S. Pat. No. 6,581,428 introduced a method and apparatus which controls the amount of material flow during the forming process. Specifically, this patent teaches control of the amount of material being drawn into the die cavity during a pre-forming process so as to avoid wrinkling of the material.
While the method and apparatus of U.S. Pat. No. 6,581,428 improves the resulting product by reducing the number of wrinkles there is yet room for other advancements in the technology of superplastic forming. The present invention provides such advancement by allowing for significantly faster forming times, improved material utilization, more uniform thinning and the capability of using lower cost aluminum sheet.
SUMMARY OF THE INVENTION
The disclosed apparatus for the shaping a metal sheet into a formed product includes a movable upper die, a movable blankholder acted upon by a movable cushion plate, and a fixed lower plate having a pre-forming punch disposed on top of a spacer. A gas inlet is formed through the pre-forming punch. A metallic gasket is provided on the upper side of the lower die.
The disclosed apparatus is movable between a position for the shaping of a metal sheet. In its first operating position the movable upper die is moved to an open position in which the ductile material is placed on the upper surface of the movable blankholder and the upper surface of the punch. The ductile material must be heated to a forming temperature of between about 400° C. and 525° C. before it is shaped. Heating of the ductile material may be done externally before it is placed in the apparatus. Alternatively heating of material may take place within the apparatus after the sheet is put in position on the pre-forming punch and blankholder.
In the second operating position of the disclosed apparatus the upper die is moved downward to press upon the ductile material thus capturing the ductile material between the upper die and the blankholder.
In the third operating position the downward movement of the upper die continues effecting the downward movement of the blankholder and its associated movable cushion plate such that the lower side of the blankholder presses against the metallic gasket, thus pre-forming the part and creating a sealed chamber.
A gas is then injected into the sealed chamber and the formation of the part is completed. Once formation of the part is completed the apparatus is returned to its first operating position so that the finished part may be removed and a new sheet of ductile material may be put in position for forming.
An aspect of the present invention is to prevent the wrinkling of the finished part. This is achieved in part by providing a punch having side walls which are large relative to the inner forming surface of the upper die and the restraining walls of the blankholder. Using this configuration the gaps between the side walls of the punch and the inner forming surface of the upper die are reduced thus achieving a pre-form having edges that are more sharply defined than known in prior approaches to superplastic forming. Furthermore, the gap between the punch and the metal restrained in the blankholder is essentially removed, thus allowing better control of wrinkles. An additional aspect of having reduced tolerances between the walls of the punch and the inner forming surface of the upper die is that the pre-form (and hence the finished part) displays fewer wrinkles than those produced according to known technologies.
Other features of the invention will become apparent when viewed in light of the detailed description of the preferred embodiment when taken in conjunction with the attached drawings and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of this invention, reference should now be made to the embodiment illustrated in greater detail in the accompanying drawings and described below by way of examples of the invention wherein:
FIG. 1 is a quarter section view of a double-action mechanical pre-forming die according to the present invention;
FIG. 2 is a cross-sectional view illustrating the double-action mechanical pre-forming apparatus at its first step where the blank is placed on the blankholder;
FIG. 3 is a cross-sectional view similar to that of FIG. 2 but illustrating the upper die in its lowered position with the material being drawn into the forming cavity to create the pre-form;
FIG. 4 is a cross-sectional view similar to that of FIG. 3 but illustrating the die being sealed and gas pressure introduced to complete the formation of the part; and
FIG. 5 is a perspective view of a component formed using the method and apparatus of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In the following figures, the same reference numerals will be used to refer to the same components. In the following description, various operating parameters and components are described for one constructed embodiment. These specific parameters and components are included as examples and are not meant to be limiting.
With reference to FIGS. 1 , a quarter section view of a double-action mechanical pre-forming die apparatus for superplastic forming of a sheet of highly ductile material in accordance with the present invention, generally illustrated as 10 , is shown. The superplastic forming apparatus 10 includes a press base 12 which is fixedly mounted on a surface such as a floor (not shown). Spaced apart from the press base 12 is a movable cushion plate 14 . Referring to FIGS. 1 through 4 , the cushion plate 14 is movably supported by the press base 12 by one or more cylinders 15 and 15 ′. Two cylinders are shown, but it is understood that more cylinders can be used, depending on the need and application. As an alternative, coil springs, gas cylinders or similar resistive devices can be used.
The apparatus 10 further includes a lower die 16 . The lower die 16 is laterally supported by a frame or other support structure (not shown) and is fixed in a non-movable position relative to the press base 12 .
A metallic gasket 18 is positioned on the upper surface of the lower die 16 . Prior to placement on the lower die 16 , both sides of the metallic gasket 18 are treated with a release agent suited for elevated temperatures, such as boron nitride.
The superplastic forming apparatus 10 of the present invention further includes an upper die 20 . The upper die 20 is vertically movable with respect to the lower die 16 . As illustrated, the upper die 20 includes a forming surface 22 against which the sheet of ductile material is pressed to form the final shape of a workpiece to be produced. In an alternative configuration, the forming surface could be defined in the lower die 16 . The upper die 20 can be fabricated from cast iron resulting in savings in tooling costs.
The superplastic forming apparatus 10 additionally includes a blankholder 23 . The blankholder 23 is vertically movable and is fixed to the movable cushion plate 14 by a pair of cushion pins 26 (illustrated in FIGS. 2 through 4 ). The cushion pins 26 pass through the lower die 16 .
The blankholder 23 , the movable cushion plate 14 and the pair of cushion pins 26 move vertically as a cushion assembly. The movable cushion plate 14 rests upon the pair of gas cylinders 15 and 15 ′.
Because the material to be formed must be highly ductile, forming typically takes place at elevated temperatures. Accordingly, the lower die 16 , the upper die 20 , the blankholder 23 and the ductile material must be heated to a predetermined temperature prior to forming. This predetermined temperature depends on the composition of the alloy to be formed. To heat the lower die 16 , the upper die and the blankholder 23 electrical resistance is directly or indirectly applied to these components through supporting elements (not shown). The heat is communicated to the ductile material.
Typical materials to be formed in the superplastic forming apparatus 10 are aluminum-magnesium alloys such as alloy 5083 or 5182. These aluminum alloys have a nominal composition, by weight, of 4.0% to 5.0% magnesium and 0.25% to 1.0% manganese. Other additions include smaller amounts of chromium and copper. These alloys would be formed over a temperature range of 375° C. to 475° C.
A pre-form punch 28 is disposed on the lower die 16 and is supported by a riser 30 . The riser 30 is mounted on a punch base 31 which is itself fixedly disposed on the lower die 16 . A portion of the metallic gasket 18 is captured between the punch base 31 and the lower die 16 as illustrated in FIGS. 1 through 4 . The riser 30 can be used to adjust the elevation of the punch 28 as desired for the particular forming application. The punch 28 can take a variety of different configurations depending on the final shape of the work-piece. The punch 28 may also be placed in the upper die 20 in an alternative embodiment.
The sides and top of the punch 28 are configured in association with the ceiling and walls of the forming cavity 22 of the upper die 20 so as to provide a selected closeness therebetween. The distances between the top of the punch 28 and the ceiling of the forming cavity 22 and between the sides of the punch 28 and the walls of the forming cavity 22 may be adjusted as desired to increase or decrease tolerances. However, the objective is to make the fit between the sides of the punch 28 and the walls of the forming cavity 22 as close as possible so as to better define the configuration of the pre-formed part while minimizing wrinkling of the part. To achieve this at least some portions of the punch 28 are spaced about 10 mm or less from the inner wall of the forming cavity and the inner wall of the blankholder 23 .
The punch 28 includes a gas passage 32 that provide pressurized gas used in the forming process. The gas passage 32 is in fluid communication with a gas delivery line 34 formed through the riser 30 and through the bottom plate 14 or lower die 16 to provide pressurized gas to the gas passage 32 . While a single gas passage 32 is illustrated, the number of passages 32 may be adjusted as desired and as known to one skilled in the art.
A method of superplastic forming using the superplastic forming apparatus 10 of the present invention is set forth in FIGS. 2 through 4 . With reference thereto, the progression of steps of the forming process in accordance with the present invention is illustrated.
With reference to FIG. 2 , the superplastic performing apparatus 10 of the present invention is in its first operating position in which the blankholder 23 is moved to its raised position in which the upper surface of the blankholder 23 is generally flush with the upper surface of the punch 28 . As illustrated, the gas cylinders 15 and 15 ′ are in their extended positions and the associated bottom plate 14 is also set to its raised position. In addition, the upper die 20 has been moved to its raised position. In this manner the apparatus 10 is open to receive a sheet of ductile material 36 which is placed on the upper surfaces of the blankholder 23 and the punch 28 .
With reference to FIG. 3 , the upper die 20 is lowered to a position until its lower surface comes into contact with the sheet of ductile material 36 . This is the second operating position of the apparatus. To achieve this position, the upper die 20 continues to move in a downward direction and applies downward pressure onto the blankholder 23 which, together with the cushion plate 14 , is moved downward until the underside of the blankholder 23 rests upon the metallic gasket 18 . The gas cylinders 15 and 15 ′ are moved to their compressed positions as illustrated in FIG. 3 . The controlled downward force on the sheet of ductile material 36 permits the sheet 36 to flow into the forming cavity 22 during this pre-forming step. The flow of the sheet 36 into the forming cavity can be seen at reference numeral 38 in FIG. 3 wherein the ends 40 of the sheet 36 are spaced a distance from the outer edges of the blankholder 23 . Consequently, the amount of sheet material 36 drawn into the forming cavity 22 during this pre-forming stage is directly related to the amount of extensive force (the tonnage being between about 2 and 20 or more) applied by the downward movement of the upper die 20 and the blankholder 23 . The cushion assembly 26 provides resistance to the opposing force of the downward-moving upper die 20 . The cushion assembly 26 effectively bottoms out once the gas cylinders 15 and 15 ′ are substantially in their compressed positions as illustrated in FIG. 3 . The mechanical pre-forming deformation of the part is finished.
In FIG. 4 the next operating position of the present invention is illustrated. In this step the amount of press tonnage is increased to fully seal the forming cavity 22 in preparation to receive the forming pressurized gas. Both the metallic gasket 18 and the sheet of ductile material 36 seal the forming cavity 22 and act to prevent leakage of the forming gas. This is the die pressure sealed position in the method of the present invention. At this point the formation of the part can be completed by the application of superplastic gas pressure. A high pressure gas is injected into the underside of the sheet of material 36 by way of the gas delivery line 34 , into the gas passage 32 . This pressure forces the preformed material to conform to the configuration of the forming cavity 22 thus producing the desired shape of the finished part. The sheet of material 36 and the metallic gasket 18 ensure that no gas leakage from the forming cavity 22 will occur. During this step, the force on the upper die 20 scales with the gas pressure to avoid gas leakage from the forming cavity 22 .
Once the part is formed, the upper die 20 is raised. Concurrently, the blankholder 23 and the cushion plate 14 also return to their raised positions as illustrated in FIG. 2 . The cycle discussed with respect to FIGS. 2 through 4 can then be repeated.
A properly formed part 40 produced according to the method and apparatus 10 of the present invention is illustrated in FIG. 5 . The part 40 includes a flange 42 . As can be seen, the corners of the part 40 are relatively sharp and well-defined, while the flange 42 is free from wrinkles.
The foregoing discussion discloses and describes an exemplary embodiment of the present invention. One skilled in the art will readily recognize from such discussion, and from the accompanying drawings and claims that various changes, modifications and variations can be made therein without departing from the true spirit and fair scope of the invention as defined by the following claims.
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A method and apparatus for forming a sheet of ductile material by superplastic forming is disclosed. The method is directed to first creating a pre-form by mechanical forming in which the pre-form is created with a die and punch. Thereafter the pre-form is subjected to gas pressure in a forming cavity to complete formation of the part. A metallic gasket is provided to ensure that no pressurized gas escapes from the forming cavity.
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This is a division of application Ser. No. 465,354 filed Feb. 9, 1983 now U.S. Pat. No. 4,523,695.
BACKGROUND OF THE INVENTION
The present invention relates to a surgical stapler for applying staples to suture or close a wound or incision, particularly a surgical skin stapler for implanting skin staples in or through the skin to suture an exterior wound or incision.
Surgical staplers are used for closing or connecting conformed wound edges of tissue by implanting metal staples in the tissue. By actuation of a lever, the staple is pressed by a ram or driver against an anvil surface provided at the tip of the stapler tool and is thereby deformed, so that the parts of the staple protruding from the stapler tip are moved toward each other and penetrate into the tissue.
U.S. Pat. No. 4,179,057 discloses a surgical stapler comprising a staple magazine containing a supply of staples, a spring for advancing the staples in the staple magazine, an anvil surface provided at the stapler tip, and a driver displaceable relative to the anvil surface in a staple channel which deforms a staple supported on the anvil surface. In a stapler of the type disclosed in the aforementioned patent, the staples are advanced along a straight feed path in the staple magazine. The forwardmost staple lies in the path of movement of the driver which extends at an angle which appears to be about 50° with respect to the longitudinal axis of the staple magazine. The stapler is actuated in plier fashion to advance the driver which presses the forwardmost staple protruding from the stapler tip against the anvil surface and deforms it to close the staple side portions. At this point, the staple has been implanted and it is necessary to remove from the staple the anvil surface which is fixed to the stapler tip. However, if the stapler has been improperly positioned, it is possible to pull the closed staple out of the tissue when disengaging the anvil surface from the implanted staple.
U.S. Pat. No. 4,202,480 discloses a surgical stapler which also comprises a staple magazine having a straight staple feed path. The staple channel in the stapler in which the driver is displaceable and the staple magazine meet at almost a right angle. The forwardmost staple is advanced by the driver to the anvil surface on which it is deformed with its side portions protruding forwardly of the stapler tip. The anvil surface is transversely disposed at the forward end of the staple channel. It is also difficult to pull the anvil surface of this stapler out of an implanted staple.
U.S. Pat. No. 3,819,100 discloses a surgical stapler comprising a removable staple cartridge which is inserted into and locked to the stapler. The staple cartridge has a straight staple feed path. Staples are advanced by a driver moved by a stepping mechanism. The forward housing portion of the stapler, into which the staple cartridge is inserted, is rotatable relative to the rear housing portion. The anvil surface is fixed at the front end of the staple cartridge.
Prior art surgical staplers have the disadvantage that they did not afford a good view of the work area because the driver moved transversely to the straight staple magazine. Therefore when the stapler was positioned for use, a considerable portion of the work area was obscured. While it is possible to arrange and feed the staples laying flat one behind the other in order provide a slim tool tip affording a better view of the work area, the cost of manufacturing the parts required to accomplish this is high. Moreover, the number of staples that can be accommodated in a staple magazine if the staples lie flat one behind the other is relatively small.
OBJECTS AND SUMMARY OF THE INVENTION
It is an object of the present invention to provide a surgical stapler, particularly a skin stapler, which eliminates the possiblity of tearing an implanted staple out of the tissue or substantially disturbing it when the anvil is separated from the staple, particularly if the stapler was improperly positioned.
The above and other objects are achieved according to the invention disclosed herein which provides a surgical stapler having an anvil surface or nose movable transversely with respect to a staple channel between an operating position and a retracted position, and in which movement of the anvil surface is controlled as a function of the position of a driver in the staple channel which cooperates with the anvil surface to deform a staple.
According to the invention, movement of the anvil surface is coupled with that of the driver. When the die is moved into its operating position, the anvil surface is also automatically brought into its operating position in which it protrudes into the staple channel in which the driver moves. Advancement of the staple in the channel is stopped by the anvil surface, and deformation of the staple takes place between the anvil surface and the driver. When the die is subsequently retracted, the anvil surface moves automatically into its retracted position, so that the closed staple does not interfere with removal of the stapler instrument. According to the invention, the anvil surface and the driver are brought into their operating positions together, the driver moving longitudinally in the staple channel while the anvil moves transversely to the staple channel.
Further objects of the present invention are to provide a stapler, particularly a skin stapler, whose tool tip is narrow and in which the staples are arranged and fed upright one against the other so that the staple magazine including the advancing mechanism can be relatively simple and yet the tool tip can be narrow, thereby covering up as little of the work area as possible. These and other objects are achieved in accordance with the invention by providing a staple magazine which extends essentially parallel to the staple channel and having at its forward end a curved section opening into the staple channel.
According to the invention, the staples are disposed in the magazine parallel to each other standing upright so that the side and the base or crown portions of adjacent staples are in contact, and are advanced by a spring. Since the forward end of the staple magazine is curved where the staple magazine opens into the staple channel, the forwardmost staple enters the staple channel in which the driver moves lying flat in the staple channel. When the die is moved to its operating position, it blocks the opening of the magazine into the staple channel so that the next staple can be advanced into the channel only after the driver has been brought back into its retracted position. Therefore, only the forwardmost staple in the magazine can be engaged by the driver as the driver is moved past the magazine opening.
According to a preferred embodiment of the invention, the anvil surface is fastened to a leaf spring which extends in the staple channel and includes an inclined surface. The driver includes a projection which cooperates with the inclined surface so that when the projection strikes the inclined surface, the leaf spring is deformed in such a way that the anvil surface is brought into its operating position. Upon release of the driver, the tension of the deformed leaf spring is released to automatically return the anvil surface into its retracted position.
For skin staplers precise guiding of the staple during the staple closing process is very important because the staple is closed as it emerges from the staple channel at the tip of the tool. According to a preferred embodiment of the invention, a notch or slot for retaining the base or crown portion of the staple during the deformation process is disposed in the anvil surface. In the initial phase of deformation, a projection or bulge in the base of the staple penetrates into the notch or slot, so that the staple is prevented from turning or pivoting. Preferably the notch or slot is located in the center of the anvil surface and the projection or bulge is symmetrically disposed in the staple. The notch or slot edges preferably dig into the staple and bring about an interlocking of the staple and the anvil surface in the central portion of the base region of the staple.
According to a preferred embodiment of the invention, the staple channel comprises side, upper and lower guide surfaces which limit movement of the forwardmost staple as it is advanced lying flat in the staple channel. The guide surfaces extend forwardly to beyond the anvil surface. An embossment positions the forwardmost staple in the staple channel upon being advanced from the magazine. From there, as the driver is advanced towards its operating position, the staple is transported to the anvil surface and feeding of additional staples from the magazine is blocked. The guide surfaces provide a well-defined advance of a staple in the channel. Preferably the guide surfaces are extended in projections of relatively small dimensions protruding forwardly beyond the anvil surface.
A two-part housing comprising a rear housing portion and a front housing portion which is rotatable relative to the rear housing portion facilitates use of the stapler. The rear housing portion contains the actuating mechanism for the driver and the front housing portion contains the driver and anvil surface which are rotatable together with the front housing portion relative to the rear housing portion. By making the front housing portion rotatable relative to the rear housing portion, the orientation of the staple relative to the actuating mechanism can be selected freely. Hence the physician need not align the actuating mechanism transversely to the wound or incision seam but can hold the instrument in the position most favorable for working the instrument.
It is important that the stapler be actuated with little effort since the instrument can only be held steady and firmly, which is required for precise setting of the staples, if the staples can be deformed and implanted with little physical force. To achieve this, the actuating element of the actuating mechanism and a lever in the rear housing portion, and the driver are coupled in such a way that the effective leverage of the lever increases as the actuating element moves further away from its inoperative position while at the same time the advancing force transmitted to the driver increases for a constant actuating force at the actuating element. In the first phase of actuation of the actuating element, the forwardmost staple of the staple magazine is simply advanced in the staple channel until it reaches the anvil surface. In this first phase the force required is relatively low. However, the maximum force that is available is required when the staple is being deformed and this maximum force occurs when the actuating element reaches its maximum travel. The amount of force required to deform the staple is reduced by the actuating mechanism disclosed herein so that it is possible to deform the staple simply by moving the actuating element with one's index finger. Compared with known staplers, the actuating force required to operate the stapler disclosed herein is reduced by about one half.
It is possible to positively couple the movement of the driver with the lengthwise movement of a slide coupled to the actuating element. However such coupling of the driver to the actuating element would be disadvantageous because the driver would follow every movement of the slide and it is possible that a second staple could enter the channel without the first staple having been deformed and released if the driver is not fully advanced to its operating position. To avoid this, according to the invention, the driver and slide are not positively coupled. Instead means are provided so that the driver is not retracted by the slide unless the driver has been advanced to its operating position. According to a preferred embodiment of the invention, a slide coupled to the actuating element is provided which includes a tongue loaded with a transverse spring action which cooperates with a control cam disposed in the housing. The tongue includes a surface which is positioned against a transverse edge of the driver and permits the driver to be retracted only after the driver has been advanced fully into its operating position. Only then can the driver be retracted and the opening of the staple magazine into the channel cleared so that the next staple can be advanced.
According to a preferred embodiment of the invention, a counting mechanism is provided which is advanced by a projection on the tongue of the slide. The counting mechanism indicates the number of staples used or the number of staples remaining in the magazine.
The above and other objects, features, aspects and advantages of the invention will be more readily perceived from the following description of the preferred embodiments thereof when considered with the accompanying drawings and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is illustrated by way of example and not limitation in the figures of the accompanying drawings in which like numerals indicate similar parts and in which:
FIG. 1 is a schematic, longitudinal section view taken through a stapler according to the invention;
FIG. 2 is a longitudinal section view taken through the tip portion of the stapler of FIG. 1 depicting the anvil surface in its retracted position;
FIG. 3 is a view similar to that of FIG. 2 depicting the anvil surface in its operating position;
FIG. 4 is a section taken along line IV--IV of FIG. 2;
FIG. 5 is a section along line V--V of FIG. 3;
FIG. 6 is a vertical section view taken through the magazine portion of the stapler of FIG. 1;
FIG. 7 is a side schematic view of a portion of the stapler of FIG. 1 illustrating the cooperation of the slide of the actuating mechanism and the driver as the driver is advanced;
FIG. 8 is a side schematic view similar to that of FIG. 7 illustrating the cooperation of the slide and the driver of the stapler of FIG. 1 shortly before the driver is retracted;
FIG. 9 is a plan schematic view of structure depicted in FIG. 8;
FIG. 10 is a vertical section view of a stapler tip including a counting mechanism according to another embodiment of the invention;
FIG. 11 is a vertical section view of a part of the rear housing of a stapler according to another embodiment of the invention depicting the actuating mechanism thereof in the retracted position of the slide; and
FIG. 12 is a view similar to that of FIG. 11 depicting the actuating mechanism in the feed position of the slide.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Preferred embodiments of the invention are illustrated and described in connection with a stapler for applying staples to an exterior wound or incision across a layer of skin, although the invention is not limited to such a surgical stapler.
The embodiment of the stapler illustrated in FIGS. 1-9 comprises as depicted in FIG. 1 a rear housing portion 10 and a front housing portion 11. The front housing portion 11 is mounted to the rear housing position for rotation of the front housing portion about its longitudinal axis. The mechanism 12 for actuating the stapler is contained in the rear housing portion 11. A slide 13 which advances a driver 15 is guided in the front housing portion 10 for longitudinal displacement but is prevented from rotating. The slide 13 comprises a forwardly projecting flexible tongue 14 which also cooperates with the driver 15, as described more fully below. The driver 15 comprises an elongated rigid strip of material which is displaceable in its longitudinal direction in a channel or duct 16. The strip has a central recess 17 (FIG. 4) at the forward end of which is disposed a bent-up section 18 having an enlarged head.
A leaf spring 19 extends in the channel 16 substantially parallel to the driver 15. The leaf spring 19 has an inclined surface 20 (FIG. 2) and is provided with a central slot 21 (FIG. 4) closed on all sides which extends forwardly and rearwardly of the region of the inclined surface 20. The enlarged head of the bent section 18 of the driver 15 protrudes through the slot 21 and is pressed against the upper side of the leaf spring 19. The forward end of the leaf spring 19 is bent downwardly to form the anvil surface 22. The rear end of leaf spring 19 is fixed to the front housing portion 11.
When the driver 15 is in its retracted position, as depicted in FIG. 2, the bent section 18 is positioned at the base of the inclined surface 20. Due to the inherent tension in the front region of the leaf spring 19, the leaf spring positions itself in the channel 16 as depicted in FIG. 2. Since the height of the channel 16 is greater than the height of the anvil 22, there is a clearance between the anvil 22 in its retracted position and the lower region 16' at the front of the channel 16.
A staple magazine 26 (FIGS. 1 and 6) extends parallel to the channel 16 in the front housing portion 11. Staples 24 are arranged in the magazine standing upright side by side and extending along the feed passage of the magazine parallel to the channel 16. A helical spring 25 braced against the housing contacts the rearmost staple and urges the rearmost staple and with it the entire stack of staples forward under constant tension. The forward section 26' of the staple magazine 26 is curved upwardly at an angle of 90° and opens into the channel 16. The staples are urged into the curved section 26' of the magazine and extend along the arc of the curve as depicted in FIG. 6, with the forwardmost staple 24' being disposed lying flat in the channel 16. The lower region 16' in the forward portion of the channel 16 in which the leaf spring 19 can move vertically is of greater width than the region above it. The height of the wider, lower channel portion 16' is only slightly greater than the thickness of the staples 24 so that channel portion 16' forms a guide channel for the advance of the forwardmost staple 24' and for the driver 15. This guide channel is defined by the lower guide face 16a, the two upper guide faces 16b, (FIG. 6), and by the lateral guide faces 16c (FIG. 4).
The staples 24, whose undeformed configuration is depicted in broken lines by the staple 24' in FIG. 5, have arcuate side portions 24a connected via a straight leg region 24b to a central base or crown portion 24c. The straight leg regions 24b extend obliquely outwardly from the base portion to the side portions 24a. The base portion 24c is semicircular with the circumference of the semicircle facing in the direction of the side portions. The base portion is engaged by the anvil surface 22 during forward motion of the staple. In order to insure centering of the staple 24, the anvil surface 22 is provided with a vertical slot 22'.
In the arcuate section 26' of the staple magazine 26, the side portions 24a of adjacent staples 24 are spaced apart while the straight leg regions 24b are in contact with adjacent leg regions due to the difference in radii of the curves for the upper and lower surfaces of the arcuate section 26'. Thus, the force of the spring 25 can be transmitted through the staples in the arcuate section 26' to the forwardmost staple 24'.
At the opening 27 (FIG. 5) of the magazine 26 into the channel 16, the underside of the upper guide face 16b is embossed (not shown) to hold the forwardmost staple 24' in a well-defined position. As the driver 15 is advanced from retracted position shown in FIG. 2; its front end abuts the forwardmost staple 24' and pushes it forward in the channel section 16'. At the same time, the bent section 18 moves along the inclined surface 20 of the leaf spring 19 so that the anvil surface 22 at the forward end of the leaf spring is brought from its retracted position into the operative position shown in FIG. 3. The staple designated 24" in FIGS. 3 and 4 is now situated between the forward end of driver 15 and the anvil surface 22 in a position in which the tips of the staple side portions protrude slightly forwardly from the instrument. As the driver 15 is advanced further, the staple side portions emerge from the front end of the instrument, with staple 24" being deformed and closed to the solid line configuration depicted in FIG. 5 in which the base 24c of the staple has been bent flat on the inner side of the anvil surface 22. To obtain as long a guide path as possible during deformation of staple 24", the guide faces 16a, 16b and 16c extend into projections 28 which define the exit gap of channel 16 out of the housing and which protrude slightly beyond the anvil surface 22.
As soon as the driver 15 has carried the forwardmost staple 24' away from the opening 27 of the magazine into the channel, the opening 27 is closed by the driver so that the next staple cannot be advanced into the channel 16. The next staple can only be advanced into the channel after the driver 15 has returned to its retracted position where it is clear of the opening 27.
FIGS. 7-9 illustrate control of the driver 15 by the slide 13. Slide 13, which is supported to the front housing portion 11 for longitudinal displacement but is prevented from rotating, comprises at its forward end a forwardly projecting, flexible tongue 14 which is vertically springloaded. A laterally projecting guide wing or cam surface 30 is disposed at the end of the tongue 14 and cooperates with a control cam 31 fixed to the housing portion 11.
When the slide 13 is advanced by the actuating mechanism 12, its front face strikes driver 15, pushing it in the direction of the tool tip. A bevel formed on wing 30 causes wing 30 to abut on a rearward bevel of the control cam 31. The tongue 14 then flexes upwardly and wing 30 slides on the upper cam surface 32. If the slide 13 is retracted before its forward end position is reached corresponding to the operating position of the driver, the wing 30 slides back on to the upper cam surface 32, which maintains the slide and correspondingly the driver in the advanced position they assumed. Only after the slide 13 reaches the position shown in FIG. 8 and the wing 30 has gone beyond the front end of the control cam 31 is the stamping operating completed and staple 24" closed. As the slide 13 is thereafter being moved back, the rear surface of the wing 30, which is inclined, contacts the correspondingly inclined forward surface of the control cam 31. As a result, the tongue 14 is forced downward, and a projection of the tongue 14 enters into the slot 17 of the driver 15. As the slide 13 is further retracted, the wing 30 is pulled beneath the control cam 31, and the driver 15 is drawn rearward. Referring to FIG. 7, after the wing 30 has passed along the underside of the control cam 31, the tongue 14 springs upward, releasing the driver 15 at its starting position. Until the driver 15 is pulled back to its starting position, it does not clear the opening 27 of the staple magazine 26 into the channel 16.
FIG. 10 depicts an embodiment in which a counting mechanism 33 is secured to the front housing portion 11. The counting mechanism is stepped by movement of the tongue 14 of the slide 13. The counting mechanism 33 comprises a hollow cylinder 34 fixed in the housing portion 11 in which is rotatably mounted a cylinder 35 having ratchet teeth 36 disposed about the periphery of the lower end thereof. A projection 37 disposed at the front end of tongue 14 engages the teeth 36 when the wing 30 is raised by the guide cam 31 during a feed movement. In this manner the cylinder 35 is rotated towards the forward end of the instrument by a predetermined angle with each feed movement of the driver 15. The top of the cylinder 35 is provided with a mark and the periphery of the hollow cylinder 34 is provided with a scale so that the mark indicates on the scale the number of staples 24 remaining in the magazine 26.
At the rear end of the front housing portion 11 is disposed a cylindrical bushing 40 (FIG. 1) in which slide 13 is coaxially mounted. The cylindrical bushing 40 can be removed from the rear housing portion 10 so that the magazine can be loaded with staples. The rear end of the slide 13 is coupled to a part 39 slidably movable along a track 42 in the interior of the rear housing portion 10. The sliding part 39 includes a sleeve 43 disposed about a shank 44 of the slide 13 which is bounded on both sides by flanges. The sliding part 39 is provided with a rack 45 having teeth or serrations which are engaged by corresponding serrations on a toothed disc segment 46. The toothed disc segment 46 forms one lever arm of a two-armed lever which pivots about a pivot pin 47 in the housing portion 10. The other lever arm 48 is engaged by a pin 49 disposed in a transverse slot 50 of a trigger lever 51. The trigger 51 is guided in a recess 52 of the handle 53 extending approximately parallel to channel 16, and is urged outwardly of the handle by a spring 54. Trigger 51 is dimensioned so that it can be actuated with the index finger when the handle 53 is gripped. The trigger, upon being pushed into the handle 53, causes the lever 46, 48 to be pivoted about the pivot pin 47 so that the sliding part 39 is advanced forwardly, and with it slide 13. Near the end position of the lever 46, 48 where it extends almost at right angles with the slide 13, leverage is the greatest, and corresponds to the stamping action of the driver. Thus, for a constant actuating force, the maximum force applied to the driver occurs during stamping.
An actuating mechanism 12' similar to mechanism 12 of FIG. 1 is illustrated in FIGS. 11 and 12. FIG. 11 depicts the retracted position of the slide 13 and FIG. 12 its advanced position. Spring 54 urges the trigger 51 out of the handle 53 and at the same time brings the sliding part 39, and with it the slide 13, into the retracted position. In the embodiment of FIG. 1 the transverse slot 50 of the trigger 51 has an angular shape, while in the embodiment of FIGS. 11 and 12, the transverse slot 50 is straight.
Certain changes and modifications of the embodiments of the invention disclosed herein will be readily apparent to those skilled in the art. It is the applicants' intention to cover by their claims all those changes and modifications which could be made to the embodiments of the invention herein chosen for the purpose of disclosure without department from the spirit and scope of the invention.
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A stapler, particularly for suturing skin wounds or incisions, is disclosed which comprises a channel in which a driver is advanced by a slide in the direction of an anvil surface. A staple magazine which extends substantially parallel with the driver includes a curved section which opens into the channel to deliver staples into the channel for engagement by the driver. During forward displacement of the driver, a projection on the driver presses a leaf spring to which the anvil surface is connected. The anvil surface at the forward end of the leaf spring is thereby brought into its operating position and is automatically moved back into its retracted position upon release of the spring after the driver is retracted. The curved section in the staple magazine enables the stapler to have a slim profile which does not obscure the working area during a stapling operation. After completion of a stapling operation, the anvil surface is automatically retracted from a closed, implanted staple.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a divisional of U.S. application Ser. No. 11/550,130 filed Oct. 17, 2006, which claims benefit of U.S. provisional application Ser. No. 60/727,300 filed Oct. 17, 2005, both of which are incorporated by reference to the extent not inconsistent herewith.
ACKNOWLEDGEMENT OF FEDERAL RESEARCH SUPPORT
[0002] Portions of this invention were made with funding from the United States Air Force, Surgeon General Office. The United States government has rights in this invention.
BACKGROUND
[0003] Envenomations by the brown recluse spider, Loxosceles reclusa , are a significant source of morbidity in endemic regions of the United States, and misdiagnoses are common. A survey of physicians in the endemic area has shown the economic viability of an accurate diagnostic test for these spider bites. An optimal Loxosceles venom assay entails significant challenges. Unlike the routine construction of enzyme-linked immunosorbent assays (ELISAs) dedicated to the detection of a single protein, this ELISA detects a unique physiologically active protein—sphingomyelinase D (SMD)—abundantly present in a venom containing a myriad of proteins in varying amounts with varying physiological properties. Some of these proteins closely resemble those of other arthropods, making cross-reactivity of proteins a challenge. However, SMD, the major component of venom felt to be responsible for dermal necrosis, has never been reported in any organism other than Loxosceles spiders.
[0004] Loxosceles (“slant-legged”) reclusa (“shy and retiring”) ( FIG. 1 ) and other species belonging to the genus Loxosceles are an occasional cause of morbidity and probably a rare cause of mortality in endemic areas ( FIG. 2 ) [Sams01, Cacy99]. Recluse populations become sporadic on either side of the range borders. (From R. Vetter: spiders.ucr.edu with new data in 2002.)
[0005] Accurate data on the number of brown recluse envenomations annually is not available. Data collected from poison control centers nationwide show 2,364 brown recluse spider bites (BRSB) reported in 2000, of which 582 had a moderately significant outcome and 21 had a major outcome. [Litovitz01] These data are incomplete and represent a fraction of the total number of probable brown recluse envenomations, which may be estimated by two other methods. Data from our survey of 21 emergency room (ER) physicians and 12 non-ER physicians ( FIG. 3 ) within the central infested area (Missouri, Kansas, Kentucky, Tennessee, Oklahoma, and Arkansas) show an average of 9.62 probable BRSB per year per ER physician. For this emergency room physician population of 3700, a BRSB annual estimate of 35,594 is obtained. For these highly infested areas, emergency room physicians estimate BRSBs comprise 0.4% of the 7.5 million ER visits, or approximately 30,000 probable BRSBs, a similar total. This total includes none of the non-ER visits, which are harder to estimate, and none of the bites out of the central infested area. The total number of possible BRSBs reported by ER physicians is higher, reflected in the total number of test kits needed per year of 17.7 per ER physician or 65,490 tests in the central infested area, an annual market of $1.7 million in central-infested-area ERs alone.
[0006] In a review of nineteen documented cases [Sams01a], the most common presenting symptom was pain at the bite site (10 of 19 patients; 53%), which is similar to the frequency of pain in a series including undocumented cases [Cacy99, Gross89]. More common on bites on the extremities, pain begins after two to eight hours and may be severe enough to require narcotics for relief. Pain may be related to sphingomyelinase D degradation of nerve sheath myelin [Clowers96] and may be followed by anesthesia, hypoesthesia, or hyperesthesia [Sams01, Clowers96]. Malaise, fatigue and lightheadedness have been reported in multiple cases, with systemic effects more common in children. Anxiety commonly pervades the first days of Loxosceles envenomation, with dread of severe necrosis or death and worry about a slowly-healing wound ( FIGS. 4 and 5 ). This is a difficult time for patients and their families, and uncertainty in the diagnosis is an additional burden. The most common of the severe systemic effects is hemolytic anemia, both Coombs-positive and Coombs-negative, which can rarely cause lysis of 70% of the red blood cell mass in hours [ouhsc96]. Rarely, disseminated intravascular coagulation may occur [Shenefelt97, Taylor66]. Eight deaths have been recorded in the medical literature as of early 2001, all lacking an accompanying spider for documentation, with most cases in children, generally following severe hemolysis, renal failure and multisystem failure [Sams01].
[0007] Many medical conditions cause necrotic wounds and have been misdiagnosed as necrotic arachnidism, leading to a delay in proper treatment. [Vetter98, Stoecker96, Rosenstein87, Vetter03, Oaven99]. These conditions include: anticoagulant necrosis; arthropod bite, e.g., Biting flies, and assassin bugs, kissing bugs, scorpions [Sams01, Vetter98]; atypical mycobacterial infection [Stoecker96]; Bacterial cellulitis; chemical burns; cutaneous vasculitis [Sams01]; eethyma gangrenosum [Sams01]; factitia; Foreign body [Sams01]; Herpes simplex with immunosuppression; Loxoscelism from other species, such as L. deserta , and L. arizonica, L. rufescens [Shenefelt97]; lyme disease [Rosenstein87]; lymphomatoid papulosis [Vetter03]; Necrotic arachnidism: other genera such as egenaria agrestis (Hobo spider), Rabidosa (Lycosa) antelucana, punctulata (wolf spider), Dolomedes scriptus (fishing spider), peucetia viridans (green lynx spider), Chemacanthium mildei (sac spider) [Sams01]; necrotizing fasciitis [Maisel94]; pyoderma gangrenosum as seen in FIG. 6 (pyoderma gangrenosum can be distinguished from necrotic arachnidism in cases with multiple inflammatory pustules or dusky, volcano-like hemorrhagic nodules, but a single ulcer can be suggestive of a spider bite and Loxosceles envenomations can be followed by pyoderma gangrenosum [Sams01, Hoover90]; syphilitic chancre [Cacy99]; Sweet's syndrome Sams01]; sporotrichosis [Oaven99]; tularemia [Stoecker96]; and ulcers, both diabetic and stasis [Shenefelt97].
[0008] Streptococci may be taken as the prototype for a number of bacteria that can cause necrosis. These include Clostridium difficile, Vibrio vulnificus, and Pseudomonas aeruginosa , (as well as other Gram-negative rods that cause eethyma gangrenosum). Extensive bacterial cellulitis, especially when the lesion is progressing in size and swollen diffusely, needs specific antibiotic and surgical management. In the news in 2002, there was a case of anthrax in a child in New York City, initially misdiagnosed as a spider bite. Cases of tularemia, atypical mycobacterial infections, and even multiple cases of lymphomatoid papulosis [Vetter03] have been initially misdiagnosed as spider bites. Mistaking these lesions for spider bites can have adverse consequences for the patient.
[0009] As yet, without clinical tests for loxoscelism, for cases in which the spider has not been recovered, the wound is diagnosed based upon the presence of typical morphology, a compatible history (such as a bite following putting on clothing after long storage), and whether the bite occurred within the expected territorial range. [Sams01] As an example, the wound in FIG. 7 , appearing in an email from a physician to one of the inventors, coming from an area of the country with no documented cases of loxoscelism, may well have been due to trauma or abuse rather than to Loxosceles envenomation, but we could not be certain. Unfortunately, in this case as in other such cases, the potential for litigation is present, and if this occurs, litigation outcome may depend upon an uncertain diagnosis.
[0010] A sensitive and specific clinical test has been sought for envenomations with Loxosceles reclusa . A passive hemagglutination inhibition (PHAI) test was reported to be successful in identifying Loxosceles reclusa experimental envenomations in guinea pigs, with 90% sensitivity up to three days after venom injection, and 100% specificity as far as false identification of other spider species, but the test is difficult to perform [Sams01, Barrett93]. A lymphocyte transformation test has also been developed, but is rarely used because of expense and delayed appearance of a positive test result [Berger73]. Proteins contained in Loxosceles venom are immunogenic with significant titers of anti-Loxosceles IgG antibody formation when venom is inoculated multiple times in the rabbit model [Gomez99]. However, antibody response in humans, across Loxosceles species, appears to be weak. Only four of 20 patients bitten with L. gaucho and treated with serum therapy had antibodies to L. gaucho venom [Barbaro92]. In another study, there were no antibodies to Loxosceles venom in measurements taken out to 30 days [Guilherme01]. Thus several experimental methods have been developed to detect the presence of Loxosceles venom, but none are simple enough to be commercially available for confirmation of envenomation in patients with suspected Loxosceles -induced lesions.
[0011] Immunoassay methods and devices comprising swabs used for analyzing samples are known to the art. U.S. Patent Publication No. 2005/0136553 discloses a device in which a swab is contacted by a fluid contained in a fluid chamber via a flow channel, and also containing an assay in fluid communication with the swab, the fluid chamber and the flow channel. U.S. Pat. No. 6,248,294 describes a substantially self-contained diagnostic test for collecting and analyzing a biological specimen having a tubular housing defining a specimen chamber for receiving a biological specimen collected from a swab. U.S. Pat. No. 4,582,699 discloses a kit for detection of gonorrhea in which an inert strip with antibody to the antibody to be detected immobilized thereon is inserted into the sample and subsequently exposed to a reagent for detecting binding. U.S. Pat. No. 4,916,057 describes an immunoassay procedure for detection of Chlamydia trachomatis antigen in a sample collected on a swab comprising extracting the sample from the swab with a basic solution that is subsequently neutralized before conducting the immunoassay. U.S. Pat. Nos. 5,753,262 and 4,943,522 disclose lateral flow immunoassays used as pregnancy tests. U.S. Pat. No. 5,163,441 describes a swab for collecting microbiological cultures comprising a swabbing tip made with a non-toxic polyurethane foam having open cells at its exposed surface. U.S. Pat. No. 5,084,245 discloses a device and method involving expressing liquid from the swab for analysis.
[0012] All patents and publications referred to herein are incorporated by reference to the extent not inconsistent herewith for the purpose of providing written description and enablement of art-known aspects of this invention.
SUMMARY
[0013] An optimal Loxosceles venom assay entails significant challenges. Unlike the routine construction of ELISAs dedicated to the detection of a single protein, this ELISA detects a unique physiologically active protein—sphingomyelinase D (SMD) abundantly present in a venom containing a myriad of proteins in varying amounts with varying physiological properties. Some of these proteins closely resemble those of other arthropods, making cross-reactivity of proteins a challenge. However, SMD, the major component of venom felt to be responsible for dermal necrosis, has never been reported in any organisms other than in Loxosceles spiders. The limits of sensitivity were previously unknown, and our research has allowed an estimate of both the smallest amount of venom detectable as well as the clinical time limits of the assay and preliminary determination of sensitivity and specificity with biological controls. We have also compared polyclonal antibodies raised in sheep and rabbits, both via crude venom inoculations and sphingomyelinase D, highly purified from crude venom via affinity chromatography. We have determined that polyclonal antibodies raised in rabbits allow more sensitivity in the polyclonal ELISA assay than those raised in sheep. Clinical application of an optimized assay saves the morbidity and expense due to inappropriate diagnosis and treatment of various skin conditions with presentations similar to Loxosceles envenomations. In addition, techniques used in the successful detection of this spider venom can be broadly applied and enable the production of assays for the detection of other clinical relevant protein markers for other envenomations and other foreign proteins.
[0014] This invention provides a method of diagnosing a bite or sting of a venomous organism in a patient having symptoms consistent with such a bite or sting. The patient can be a human or animal such as a mammal. The method comprises collecting a sample comprising venom from said venomous organism from the area of the suspected bite or sting using a swab; contacting the sample with an antibody which specifically binds to an antigenic site on venom present in the sample; and detecting a complex formed by binding of the antibody and the antigenic site. Venom is a poisonous secretion of a venomous organism, such as a snake, spider, scorpion, wasp, bee, or jellyfish, usually transmitted by a bite or sting. The term “diagnosing” as used herein means identification of the venomous organism that produced the injury. To “collect a sample comprising venom” means to obtain a sufficient amount of material from the site of the bite or sting to be able to diagnose the bite or sting. The material containing the venom can be blister fluid or tissue and/or liquid from a lesion or surrounding skin. The “area of the bite” means an area about one cm of a visible wound (over a diameter of 2 cm, with this diameter ranging from about 1-5 cm).
[0015] A swab is a piece of absorbent or adsorbent material, which means material capable of taking up material containing venom from the site of a bite or sting. The material can be any such material known to the art, e.g., cloth comprised of natural or synthetic materials, e.g., cotton, bibulous paper, Dacron rayon, or nylon, or fibers made of such materials, e.g., cotton balls, medical gauze, paper, sponge, polymeric foam such as polyurethane foam, brushes with absorbent or adsorbent bristles that allow the collection of cells such as the Cytette nylon brushes of Birchwood Laboratories, Inc., Eden Prairie, Minn. that are useful for rotation within a narrow aperture, or the Panasonic electric shaver cleaning brush available through totalvac.com; and Q-tip™-type devices such as the cotton swabs made by Unilever Company, and the rayon Scopette™ swabs of Birchwood Laboratories, Inc., typically modified to have a larger head. Bristles that are not absorbent or adsorbent taken singly, can be combined into “brushes” that are absorbent or adsorbent and capable of picking up sample material. The absorbent or adsorbent material can be attached to a stick or other handle or can be manipulated by hand without a handle. The swab may be dry, in which case fluid such as saline can be added to carry the antigens on the swab into contact with antibodies in the immunoassay, or the swab may be premoistened with a fluid such as saline as supplied as part of an immunoassay kit, or may be premoistened by the user at the time of taking the sample.
[0016] The method of collecting the sample is non-invasive, and does not require cutting or injecting needles into patients who are typically anxious and in pain, and who may be children or elderly people who do not tolerate pain well.
[0017] The detecting can be performed by any method known to the art, as more fully described hereinafter, including sandwich immunoassays and electrochemical immunoassays. In addition, other means for determining the presence or absence of a selected venom protein, e.g., performing western blots, tests, protein function tests, and other assays known to the art can be used.
[0018] In one embodiment, the detecting is done using an immunoassay device “in the field,” i.e., outside a laboratory. Such devices include, for example, cartridge test devices and dipstick test devices. The device comprises at least one first monoclonal and/or polyclonal antibody specific to a venom protein, a support for the first monoclonal or polyclonal antibody, means for contacting the first monoclonal or polyclonal antibody with the sample, and an indicator capable of detecting binding of the first monoclonal or polyclonal antibody with the venom protein. In some embodiments, one or more monoclonal antivenom antibodies are used in addition to polyclonal antibodies. The swab can have the anti-venom antibody or antibodies immobilized thereon, and can thus be an integral part of the immunoassay device. For example it can be a paper strip that is subsequently contacted with a tracer to detect the presence of binding between venom antigens and the antibodies. The swab can comprise a liquid to aid in picking up venom-containing material from the site. In some embodiments, after collecting the venom from the site of the suspected bite or sting, the swab can be wiped over a substrate having immobilized antibody thereon, or exposed to a liquid that carries the venom antigens from the swab to a site where they can be contacted with anti-venom antibodies. Or venom-containing liquid can be squeezed from or otherwise extracted from the swab for contact with anti-venom antibodies. In some embodiments, the swab is disposable.
[0019] Typically, the sample is collected by gently wiping or soaking the skin with the swab for about one to about 360 seconds, for example, for about thirty seconds. The swab can be flash-frozen to extend the period between taking the sample and testing longer than the seven days to three weeks possible without freezing.
[0020] When cells are included in the sample to be tested, the method and/or device can include a cell-lysing step or means using detergent, puncture or other physical or chemical process known to the art.
[0021] In the devices of this invention, any indicator means known to the art to detect antibody/protein binding can be used. The indicator means can include second, labeled, monoclonal or polyclonal antibodies which bind to the selected protein, which preferably bind to a substantially different epitope on the selected protein from that to which the first monoclonal or polyclonal antibodies bind, such that binding of the first monoclonal or polyclonal antibody will not block binding of the second antibody, or vice versa. The indicator means can also include a test window through which labeled antibodies can be viewed. Any label (also referred to herein as marker) known to the art can be used for labeling the second antibody. The second antibody can be monoclonal or polyclonal.
[0022] When the sample to be assayed is a liquid or is carried by a liquid, and the immunoassay test device is a lateral flow device comprising inlet means for flowing a liquid sample into contact with the antibodies, the test device can also include a flow control means for assuring that the test is properly operating. Such flow control means can include control antigens bound to a support which capture detection antibodies as a means of confirming proper flow of sample fluid through the test device. Alternatively, the flow control means can include capture antibodies in the control region which capture the detection antibodies, again indicating that proper flow is taking place within the device. In a lateral flow device, in which the sample is placed on an absorbent support comprising the detection antibody, the sample window and absorbent support provide means for contacting the antibodies with the sample.
[0023] The assay method can also comprising collecting a control sample from a separate site on the patient's body that has not been exposed to the venom, i.e., shows no sign of having been the site of a venomous sting or bite, and the control can be tested using the same immunoassay methods and devices as the sample from the site of the sting or bite.
[0024] Many venomous organisms are known to the art, including spiders such as the brown recluse, black widow, funnel web, funnel red, white tail, red back, mouse spider, house spider, wolf spider, trap-door spider, and tarantulas, as well as scorpions, and venomous snakes, such as the eastern diamondback rattlesnake ( Crotalus adamanteus ), the timber rattlesnake ( Crotalus horridus ), the dusky pigmy rattlesnake ( Sistrurus miliarius barbouri ), the Mojave rattlesnake ( Crotalus scutulatus ), the common adder ( Opera berus ), the fer-de-lance ( Bothrops atrox ), the Florida cottonmouth ( Agkistrodon piscivorus conanti ), the eastern coral snake ( Micrurius fulvius fulvius ), and other venomous snakes known to the art. Venomous organisms also include jellyfish such as the box jellyfish ( Chironex fleckeri ), and the irukandji jellyfish ( Carukia barnesi ); wasps and bees. Venomous spiders of genus Latrodectus, Tegeneria (including Tegeneria agrestis ), Loxosceles, Atrax (including Atrax robustus ), Phoneutri , and hadronyche (including the species Hadronyche formidabilis, H. infensa, H. valida, H. versuta, H. modesta, H. meridiana, H. adelaidiensis, H. eyrei, H. flindersi, H. venenata, H. pulvinator and H. cerberea ) are included within the venomous organism whose stings or bites can be diagnosed by the methods and devices of this invention. The invention is illustrated with respect to the diagnosis of bites of the brown recluse spider, Loxosceles Reclusa . Other spiders within this genus for which the method is applicable include Loxosceles intermedia, Loxosceles laeta, Loxosceles gaucho , and Loxosceles rufescens.
[0025] This invention provides an improved method for detecting venom by means of an ELISA modified to reduce blocking antibodies using nonfat milk solids and alkaline phosphatase markers. A variety of markers may be used including immunogold, alkaline phosphatase, beta-galactosidase, glucose oxidase, peroxidase markers, and any enzyme that produces a colored or fluorescent product, as is known to the art for monitoring immune reactions. This ELISA is extremely sensitive and can detect under 24 picograms, e.g., around 20 picograms, of venom in a sample, even after the sample has been exposed to ambient summertime temperatures, e.g., up to 100° F. or more for up to about three weeks prior to the detecting step. The method can distinguish the organism that caused the bite or sting from other species of venomous organism utilizing antibodies specific to particular venoms, which can be produced by methods known to the art, following the teachings herein, using combinations of venom immunoassays with previously-known clinical identification of symptoms. Methods of raising polyclonal antibodies can be optimized over host species. A comparison of species can allow optimization when the optimal species is unknown, as per the sheep and rabbit results above. A suitable species can be determined for any given venom by comparing known methods, for example the production of polyclonal antibodies to scorpion venom in horses, to another species, for example sheep.
[0026] This invention also provides an immunoassay kit comprising an antibody capable of binding to an antigen present in a venom; a swab for collecting a sample comprising venom from the area of a venomous bite or sting on a patient's body; and a tracer for detecting binding between the antibody and the antigen. In some embodiments the antibody is immobilized on a solid substrate, and the solid substrate can be a swab as described above.
BRIEF DESCRIPTION OF THE FIGURES
[0027] FIG. 1 depicts a Loxosceles reclusa spider feeding on a grasshopper.
[0028] FIG. 2 is a map of the United States showing endemic distributions of the brown recluse (larger area) and five related Loxosceles species in the United States, based on Gertsch and Ennik.
[0029] FIG. 3 is a graph showing the results of a telephone and email survey of 33 physicians within the L. reclusa area shown in FIG. 2 .
[0030] FIG. 4 shows a severe bite of Loxosceles reclusa , with a Sams-King certainty of probable on the eighth day.
[0031] FIG. 5 shows a severe bite of Loxosceles reclusa , with a Sams-King certainty of probable, on the 28th day, illustrating the typical slow healing course for large, ulcerated lesions.
[0032] FIG. 6 shows a Pyoderma gangrenosum ulcer. Note the typical wet, clean-based ulcer and violaceous overhanging border.
[0033] FIG. 7 shows a necrotic wound with uncertain diagnosis coming from an area in which Loxosceles recluse is known to be present.
[0034] FIG. 8 shows venom fractionation using Sephadex G100 column chromatography. The first peak (arrow) fraction was found to contain dermonecrotic activity. Peaks 6 and 7 may contain the 5 kDa protein shown in FIG. 9 .
[0035] FIG. 9 shows an SDS PAGE (electrophoresis) gel of fractions of crude Loxosceles venom (VEN) and analysis of crude venom (see lane marked “VEN”). The multiple protein bands noted in this SDS PAGE demonstrate the multiple proteins contained in venom.
[0036] FIG. 10 shows Western blots of L. deserta (LoxD) and L. reclusa (LoxR) using αLoxRD as the primary antibody. Both venoms revealed prominent signaling in the 30 KDa molecular weight range.
[0037] FIG. 11 shows Polyclonal-based ELISA of homogenized dermis from a punch biopsy from an Arizona L. deserta victim (see left arrow—positive result is shown in triplicate and underscored.) Compare with the control dermal punch biopsy from a car trauma victim (right arrow).
[0038] FIG. 12 shows results of standard ELISA at dilutions of 1:100 on sera from patients with probable Loxosceles envenomations, against fractions 1-8 of venom and two lots of crude venom and sphingomyelinase, comprising the majority of fraction 1. Preliminary results showed a response by patient 3 at 21 weeks to total venom and other fractions. Note minimal early response and minimal response to sphingomyelinase. Patient 1, week 1=front row; Patient 1, week 5=second row; Patient 2, week 1=third row; Patient 3, week 21=back row.
[0039] FIG. 13 shows arthropod venoms that cross-reacted to the Loxosceles species ELISA at 16,000 ng and 2,000 ng. Only L. reclusa control venom reacted with the ELISA at 40 ng. For graphic purposes, the y-axis values are reported as log(data).
[0040] Values reported as off the scale by the assay. From [Gomez02].
[0041] FIG. 14 compares venom standard curves for polyclonal assays using alkaline phosphatase (AP) and horseradish peroxidase (HRP). Detection threshold is 24 pg/well for AP and 49 pg/well for HRP.
[0042] FIG. 15 graphs results of polyclonal assays of injected L. reclusa venom, 3-week using whole venom ng, recovered from cotton swabs at the infection site.
[0043] FIG. 16 graphs results (averaged over all rabbits) of polyclonal assays of injected L. reclusa venom, 3-week using whole venom ng, recovered from Dacron swabs at the infection site.
[0044] FIG. 17 graphs results of polyclonal assays of injected sphingomyelinase component of L. reclusa venom ng, 3-week, recovered from Dacron swabs.
[0045] FIG. 18 graphs 3-week ng venom recovered from saline-injected animals, cotton swabs. Each line represents a single rabbit, with a diamond, for example, representing a single rabbit, and a square representing a different rabbit.
[0046] FIG. 19 graphs 3-week ng venom recovered from saline-injected animals, cotton swabs. As in FIG. 18 , each line represents a single rabbit, with a diamond, for example, representing a single rabbit, and a square representing a different rabbit.
[0047] FIG. 20 shows results of assays on six specimens with vertical axis showing pg/well of venom recovered, with raw absorbances corrected for control absorbances. Patients A, B, and C were all judged clinically consistent with Loxosceles envenomations, however negative ELISAs provided strong evidence against Loxosceles envenomation. Venom concentrations on all three were less than 0.32 pg, shown in the graph as 0.16 pg. Patient D was clinically assessed as a staphylococcal envenomation and culture confirmed MRSA, however the markedly positive ELISA established concomitant loxoscelism. Patient T from Turkey, and patient S from St. Louis were assayed via gauze and blister fluid, respectively, received via express mail. Of the six cases, a brown recluse spider was found only for patient S.
[0048] FIG. 21 depicts the skin appearance of Case B ( FIG. 20 ), showing a bloody blister in a young female, which was rated as a probable Loxosceles envenomation but the level of venom antigen via cotton swab was less than 0.32 pg.
[0049] FIG. 22 depicts a painful swollen tender lesion on the foot in a young male (Case D, FIG. 20 ) with a documented staphylococcal infection at the site with a 5-day history. This was considered to be a staphylococcal infection alone and not a recluse bite until ELISA showed significant venom antigen via cotton swab: 1.2 picogram.
[0050] FIG. 23 depicts a tender eyelid lesion in a Turkish patient (Case T, FIG. 20 ) under the care of an ophthalmologist, presenting with considerable swelling and painful draining eyelid lesion with hemorrhage and massive bilateral eyelid and facial edema. Gauzes were used to wipe the affected and contralateral sites, with shipping to Missouri taking one week. ELISA showed significant venom antigen when compared to control via the gauze method of collection: 0.5 picogram.
[0051] FIG. 24 depicts a hemorrhagic bullae on the arm of a child (Case S, FIG. 20 ) who was playing in his mother's sewing room, when a toy got stuck behind a stack of boxes, and he stuck his arm behind the stack to retrieve it. His mother recovered the spider, identified as L. reclusa by physicians. Significant hematuria and hemolysis marked his hospital course and morphine was needed for pain control. Blister fluid showed significant venom antigen by ELISA: 0.6 picogram.
[0052] FIG. 25 shows a small painful lesion in 10-year-old Missouri girl caused by a Loxosceles reclusa spider bite.
[0053] FIG. 26 shows an alkaline phosphatase detection sensitivity curve for venom detection, with venom standards shown as squares and amount detected for the patient depicted in FIG. 25 as a diamond.
[0054] FIG. 27 shows Patient T, Case 1 of Example 8 (see also FIGS. 20 and 23 ) after healing. No scarring or functional impairments were seen at seven months.
[0055] FIG. 28 shows Patient Case 2 of Example 8 presenting with a painful eyelid lesion with early necrosis and severe bilateral eyelid and facial edema.
[0056] FIG. 29 shows the Patient of FIG. 28 with scarring and hyperpigmentation observed four months after the spider bite.
[0057] FIG. 30 shows alkaline phosphatase detection standard curves, for Case 1, FIG. 27 , showing venom standards as black squares and recovered ELISA venom amount (4.50 pg) at circle.
[0058] FIG. 31 shows alkaline phosphatase detection standard curve for Case 2, FIG. 28 , showing venom standards as black squares and recovered ELISA venom amount (8.2 pg) at circle.
DETAILED DESCRIPTION
[0059] Loxosceles reclusa and related arachnid species are indigenous American spiders that possess a venom capable of causing painful, disfiguring necrotic ulcers with surrounding dermal inflammation and uncommonly, severe systemic effects [Atkins58, Wasserman83, Sams01, Anderson97]. The diagnosis of a brown recluse spider bite is a clinical one made on the basis of the morphologic appearance of the cutaneous lesion [Atkins58, Wasserman83, Sams01, Anderson97]. Definitive diagnosis is problematic because patients generally do not bring the offending spider to the clinician for identification. The appearance of significant envenomation with cutaneous necrosis is the usual basis for diagnosis but is not specific for Loxosceles species envenomation [Sams01, Anderson97, Vetter98], with mimics including a variety of treatable illnesses [Rosenstein87, Rees87, Moaven99]. When significant necrosis is absent, the characteristic features of envenomation are lacking, and the diagnosis is more difficult.
[0060] Physicians who practice within the Loxosceles reclusa habitat in the central and southern areas of the Midwestern US routinely see patients with suspected spider bites. Unfortunately, we have observed that fewer than 10% of patients bring in the suspect spider for identification. The spider may be found after a significant delay, leading to some uncertainty that the arachnid presented is the offending agent. Therefore, the diagnosis of most spider bites is generally dependent upon analysis of the bite morphology. Severe bites may exhibit the ‘red, white and blue’ sign described by Sams et al [Sams01] or may show the sunken, bluish patch described by Anderson [Anderson97]. Small bites as described herein lack these features and are not well-characterized. They are likely more frequent in occurrence than the literature suggests. Small bites cannot be diagnosed definitively without the spider or a test that can unequivocally demonstrate the presence of spider venom.
[0061] Utilizing the diagnostic tests of this invention, venomous bites can be correctly diagnosed. A sample comprising venom is collected from the area around the bite using a swab, and the material on the swab is immunologically analyzed for the presence of venom.
[0062] Various formats may be used to test for the presence or absence of an analyte using the assay. For instance, in certain embodiments, a “sandwich” format is utilized. Examples of such sandwich-type assays are described by U.S. Pat. No. 4,168,146 to Grubb, et al. and U.S. Pat. No. 4,366,241 to Tom, et al., which are incorporated herein in their entirety by reference thereto for all purposes. In addition, other formats, such as “competitive” formats, may also be utilized. In a competitive assay, the labeled probe is generally conjugated with a molecule that is identical to, or an analogue of, the analyte. Thus, the labeled probe competes with the analyte of interest for the available receptive material. Competitive assays are typically used for detection of analytes such as haptens, each hapten being monovalent and capable of binding only one antibody molecule. Examples of competitive immunoassay devices are described in U.S. Pat. No. 4,235,601 to Deutsch, et al., U.S. Pat. No. 4,442,204 to Liotta, and U.S. Pat. No. 5,208,535 to Buechler, et al., which are incorporated herein in their entirety by reference thereto for all purposes. Various other device configurations and/or assay formats are also described in U.S. Pat. No. 5,395,754 to Lambofte, et al.; U.S. Pat. No. 5,670,381 to Jou, et al.; and U.S. Pat. No. 6,194,220 to Malick, et al., which are incorporated herein in their entirety by reference thereto for all purposes.
[0063] Any known detection technique may be utilized in the present invention. For example, as is well known in the art, the assay may also be an electrochemical affinity assay, which detects an electrochemical reaction between an analyte (or complex thereof) and a capture ligand on an electrode strip. For example, various electrochemical assays are described in U.S. Pat. No. 5,508,171 to Walling, et al.; U.S. Pat. No. 5,534,132 to Vreeke, et al.; U.S. Pat. No. 6,241,863 to Monbouquette; U.S. Pat. No. 6,270,637 to Crismore, et al.; U.S. Pat. No. 6,281,006 to Heller, et al.; and U.S. Pat. No. 6,461,496 to Feldman, et al., which are incorporated herein in their entirety by reference thereto for all purposes.
[0064] A concern in performing diagnostic assays is to separate immunoreactants that do not bind antigen, and thus do not form part of the immune complex, from bound reactants that form the complex. The presence of unbound reactants can increase the background of the assay. While washing the immune complex can, and, indeed, does remove most of the background signal due to unbound reactants, most assays employ what is termed a blocking step to further reduce the background. The blocking step involves coating the solid support with proteinaceous substances after it has been coated with antibody. The blocking material binds to sites on the solid matrix material which are not covered with antibody, and thus prevents subsequent nonspecific binding of immune reactants that are not part of the immune complex. Generally, the blocking step is performed either before the assay is conducted, hence, necessitating an additional time consuming step, or else, as described in U.S. Pat. No. 3,888,629, the solid matrix material is impregnated with the blocking agent, and then freeze dried and maintained in this state prior to use.
[0065] Immunoassay devices suitable for detecting the presence of venom can be in the form of flow-through assay devices, typically contained within a housing, and suitable for collecting samples outside a laboratory. For example, a flow-through immunoassay comprises a porous membrane having a binding reagent immobilized on the membrane. An absorbent material is placed on one side of the membrane. When a sample containing an analyte is applied to the membrane, the sample flows through the membrane by capillary movement. The analyte is then bound to the binding reagent. The assay device may include an absorbent (bibulous) support upon which antivenom antibody is present, and into which sample venom components are absorbed directly upon contact with the swab or by means of a carrier liquid that carries the venom components from the sample on the swab into the absorbent support. The device may also comprise a receiving well for receiving the sample or sample components, preferably having a bibulous material therein to facilitate transfer of the antigens into the well. The receiving well may incorporate the antivenom antibodies.
[0066] In one embodiment, the immunoassay test is a colorimetric test that comprises a plastic housing with a well disposed in one end thereof comprising a bibulous material; and a strip of paper in fluid communication with the well extending toward the other end of the housing and having two stripes about 1.5 mm in width running the entire width of the strip, one for control prepainted with venom antigens and antivenom antibodies, as well as markers to indicate binding of the antigens and antibodies, and the other for performing the test prepainted only with antivenom antibodies and markers to indicate binding. When the sample is added to the well by rubbing the swab along with a carrier liquid such as normal saline, the carrier fluid allows binding contact between the prepainted antigens and antibodies on the control stripe and carries venom antigens from the sample into binding contact with the antivenom antibodies on the test stripe. The housing comprises a window or windows positioned above the stripes and is marked to indicate control and test (e.g., C and T). The control stripe always shows the color reaction, but the test does not unless the sample contains venom antigens with which the prepainted antivenom antibodies bind.
[0067] A flow-through immunoassay further comprises applying a tracer that is another binding reagent of the analyte with a label for detecting the bound analyte. The binding reagents of the membrane and tracer are selected from a group consisting of antibodies, antigens, receptor proteins, etc. The label can be selected from a group of detectable substances, including enzymes, radioactive isotopes, and particular color particles. The immunoassay can also comprise detector means known to the art for detecting the presence of the label or changes in the label that indicate that binding of a tracer antibody to the detection antibody has occurred. Suitable membranes include glass fiber, polyvinylidene difluoride, polycarbonate, nitrocellulose, nylon, paper, etc., for example as described in U.S. Pat. No. 5,155,022.
[0068] As is known in the art, antibodies useful for detecting venom may be polyclonal or monoclonal antibodies, and polyclonal, monoclonal antibodies or both may be used as tracers. Antibodies which bind to venom polypeptides can be prepared using an intact polypeptide or fragments containing small peptides of interest as the immunizing antigen. The polypeptide or a peptide used to immunize an animal can be derived from translated cDNA or chemical synthesis which can be conjugated to a carrier protein, if desired. Such commonly used carriers which are chemically coupled to the peptide include keyhole limpet hemocyanin (KLH), thyroglobulin, bovine serum albumin (BSA), and tetanus toxoid. The coupled peptide is then used to immunize the animal (e.g., a mouse, a rat, or a rabbit).
[0069] If desired, polyclonal or monoclonal antibodies can be further purified, e.g., by binding to and elution from a matrix to which the polypeptide or a peptide to which the antibodies were raised is bound. Those of skill in the art will know of various techniques common in the immunology arts for purification and/or concentration of polyclonal antibodies, as well as monoclonal antibodies. See, e.g., Coligan, et al. (current ed.) Current Protocols in Immunology, Wiley Interscience.
[0070] It is also possible to use anti-idiotype technology to produce monoclonal antibodies which mimic an epitope. For example, an anti-idiotypic monoclonal antibody made to a first monoclonal antibody will have a binding domain in the hypervariable region which is the “image” of the epitope bound by the first monoclonal antibody.
[0071] The preparation of polyclonal antibodies is well-known to those skilled in the art. See, e.g., Green, et al. “Production of Polyclonal Antisera” pages 1-5 in Manson (ed.) Immunochemical Protocols Humana Press; Harlow and Lane; and Coligan, et al. Current Protocols in Immunology.
[0072] The preparation of monoclonal antibodies likewise is conventional. See, e.g., Kohler and Milstein (1975) Nature 256:495 497; Coligan, et al., sections 2.5.1 2.6.7; and Harlow and Lane Antibodies: A Laboratory Manual, Cold Spring Harbor Press. Briefly, monoclonal antibodies can be obtained by injecting mice with a composition comprising an antigen, verifying the presence of antibody production by removing a serum sample, removing the spleen to obtain B lymphocytes, fusing the B lymphocytes with myeloma cells to produce hybridomas, cloning the hybridomas, selecting positive clones that produce antibodies to the antigen, and isolating the antibodies from the hybridoma cultures. Monoclonal antibodies can be isolated and purified from hybridoma cultures by a variety of well-established techniques. Such isolation techniques include affinity chromatography with Protein-A Sepharose, size-exclusion chromatography, and ion-exchange chromatography. See, e.g., Coligan, et al.; Barnes, et al. “Purification of Immunoglobulin G (IgG)” in Methods in Molecular Biology, vol. 10, pages 79 104 (Humana Press, current ed.). Methods of in vitro and in vivo multiplication of monoclonal antibodies are well-known to those skilled in the art. Multiplication in vitro may be carried out in suitable culture media such as Dulbecco's Modified Eagle Medium or RPMI 1640 medium, optionally replenished, e.g., by a mammalian serum such as fetal calf serum or trace elements and growth-sustaining supplements such as normal mouse peritoneal exudate cells, spleen cells, bone marrow macrophages. Production in vitro provides relatively pure antibody preparations and allows scale-up to yield large amounts of the desired antibodies. Large scale hybridoma cultivation can be carried out by homogenous suspension culture in an airlift reactor, in a continuous stirrer reactor, or in immobilized or entrapped cell culture. Multiplication in vivo may be carried out by injecting cell clones into mammals histocompatible with the parent cells, e.g., syngeneic mice, to cause growth of antibody-producing tumors. Optionally, the animals are primed with a hydrocarbon, especially oils such as pristane (tetramethylpentadecane) prior to injection. After one to three weeks, the desired monoclonal antibody is recovered from the body fluid of the animal.
Example 1
Venom Fractionation
[0073] Commercially available Loxosceles sp. spider venoms (SpiderPharm, Yarnell Ariz.) are crude uncharacterized preparations containing multiple polypeptides ranging in size from 10-200 KDa. The purification and biochemical characterization of the active components in these mixtures is fundamental to understanding the potent inflammatory and necrotic effects that these venoms have on skin. We have completed preliminary fractionation of Loxosceles sp. venom using anion exchange chromatography. Crude venom was loaded on a HiTrap Q column and eluted with a salt gradient increasing from 20 mM to 1M NaCl in 25 mM TEA buffer pH 7.4. While two earlier studies found three venom fractions in Loxosceles sp. using Sephadex G50 and Sephadex G100 column chromatography, the higher resolution of the more sensitive methods used in our studies found two more venom component fractions. Thus, five fractions (to the left of fractions 6-7, FIG. 8 ) were separated and assayed using the rabbit model of arachnid envenomation. We found using the rabbit dermal model for Loxosceles envenomation that the dermonecrotic activity was found in the first (flow-through) fraction, the leftmost peak.
[0074] FIG. 9 shows the results of SDS PAGE analysis of crude venom (see lane marked “VEN”). The multiple protein bands noted in this SDS PAGE demonstrates the multiple proteins contained in venom.
Example 2
Characterization of Venom Proteins Via Western Blot
[0075] L. deserta, L. reclusa venoms and Rainbow™ molecular weight marker (Amersham International, Buckinghamshire, England, RPN 800) were subjected to electrophoresis on 10% sodium dodecyl sulfate (SDS)-polyacrylamide gels and transferred to nitrocellulose [Osborn89]. Blots were analyzed for protein components using αLoxRD (rabbit polyclonal) as the primary antibody at 2 ug/ml. The antibody predominantly recognized a protein(s) migrating close to 28,000M r . See FIG. 10 .
Example 3
Serum Loxosceles Ag or Ab Detection vs Polyclonal Swab ELISA
[0076] Tests were performed to determine whether detection of antibodies in human sera to one or more components of Loxosceles venom is an alternate avenue for development of a reliable clinical test, and whether the venom protein can be detected in serum.
[0077] ELISA titration of human sera from three patients with suspected Loxosceles envenomations, with both acute and convalescent sera from patient 3, was performed with whole venom (SpiderPharm, Yarnell Ariz.) and fractionated venom, using the eight protein fractions shown in FIG. 8 . All three patients had probable Loxosceles envenomations by the criteria of Sams [Sams01]. Wells were coated with 100 ng of buffered crude venom and venom fractions 1-8, and optical densities taken at 30 minutes. Antibodies from patient 1 were obtained 7 days post spider bite, from patient 2-9 and 24 days post spider bite, and from patient 3-150 days post spider bite.
[0078] Readings of the four patient sera were compared with control human sera. A standard ELISA with biotinylated goat antihuman secondary IgG at dilutions of 1:100 was then performed. There was a response by patient 3 at 21 weeks to total venom, with a significant response to fraction 6 and other fractions, as shown in FIG. 11 . No significant antibody titers were detected early.
[0079] ELISA assays of serum for venom have also been attempted. Four serum samples taken at 6 hours from rabbits and five more from humans at various times, including one documented envenomation, have all shown no venom detected above background levels. Accordingly, acute and convalescent antibody titers and serum venom assays aimed at confirming Loxosceles envenomation do not appear to be a viable clinical option, because of an apparently weak antibody response and because of the need for immediate diagnosis. We have accordingly developed antigen-based assays.
Example 4
Polyclonal Assays
[0080] The first polyclonal assay had a threshold of detection of approximately 100 pg per well. This was used to detect Loxosceles venom in a 4 mm punch biopsy from an Arizona Loxosceles spider bite victim [Boyer00]. See FIG. 11 . A specimen of L. arizonica was discovered in the child's bed. The positive polyclonal assay together and the finding of the spider allowed a definitive diagnosis in a child with significant hemodynamic changes resembling sepsis.
[0081] Thereafter, a second polyclonal assay was developed. This was a Loxosceles venom competitive polyclonal enzyme immunoassay that was successfully applied to detect Loxosceles venom in hair shafts and skin samples obtained from a patient with a probable Loxosceles envenomation [Miller00]. Briefly, this patient was bitten by a spider after removing materials purchased from a gun show in a southern region of the U.S. After the patient presented with clinical evidence of a spider bite, we plucked hair from the affected dermal lesion and from a control site in his opposite extremity. Using competitive sandwich polyclonal techniques described in [Miller00], we compared the less invasive hair plucking technique with dermal biopsies obtained from the affected site. Using the competitive enzyme immunoassay technique, the presence of Loxosceles venom was detected in the lesional punch skin biopsy tissue (8.2±1.5 ng/ml versus 1.5±0.7 ng/ml in contralateral negative control tissue) and in hairs plucked from the lesion (12.7±3.1 ng/ml versus 1.4±1.6 ng/ml in hairs from the contralateral leg) [Miller00]. This report showed that venom was detected by a relatively noninvasive means (i.e., hair plucking).
[0082] Our first polyclonal assay could detect Loxosceles venom with a threshold of detection of about 100 pg. Seventeen competing venoms (14 arachnids, 2 scorpions, and 1 honeybee venom) required over 2000 ng in the same assay to be detected ( FIG. 13 ). Only L. reclusa control venom reacted with the ELISA at 40 ng.
[0083] Several modifications of the first polyclonal assay have allowed a new threshold of detection, 24 pg vs 100 pg previously. The changes include adding nonfat milk solids to the blocking buffer, increasing the concentration of other blocking proteins, allowing the solution to incubate overnight and changing the developing agent to alkaline phosphatase. Venom standard curves are shown for the alkaline phosphatase (AP) assay and horseradish peroxidase (HRP) assay in FIG. 14 .
[0084] A 24 pg venom well consistently produces an AP signal that is greater than background plus 3 standard deviations. Three necrotic and inflammatory lesions (with no history or examination supporting necrotic arachnidism) had signals at background levels with the second assay.
Example 5
Time Study of Venom Detection in Rabbits Using Cotton and Dacron Swabs
[0085] This study was done under amendment #6 to US Military Protocol FWH20020003, “Effects of Venom From the Brown Recluse Spider ( Loxoceles reclusa ) on the Coagulation Mechanism in Rabbits ( Oryctolagus cunniculus ).”
[0086] In this amended protocol, FWH20020003A, the 10.0 μg/ml dose of the brown recluse spider venom was found to be a better concentration than a 20.0 μg/ml dose used in previous studies. A dose of 5 μg produces tissue damage that appears to approximate the typical “bite” observed in a brown recluse spider bite. It is probable that the actual bite yields a dose of venom that is quite variable.
[0087] This protocol was approved by the Animal Use and Care Administrative Advisory Committee (AUCAC) for the use of eighteen rabbits for the full study. The goal was to find the least amount of venom detected from a swab and the longest period after the bite that it can be detected, i.e., the longest amount of time that the venom is viable in the individual lesions. The number of test subjects was determined for statistical significance. Three animals were saline control subjects. Rabbits were injected in the deep dermis in the middorsal back. The first phase of the study was to obtain data to determine the time course of swab and biopsy venom detection. The biopsied lesions were examined histopathologically to assess the extent and nature of the tissue damage using standard techniques from previous studies.
[0088] Biopsy tissues were obtained for “snap freezing” in liquid nitrogen at 24 and 72 hours for venom antigen examination at the University of Missouri. After envenomation and swab and biopsy collections, all animals were euthanized following humane procedures approved by the AUCAC. In the second phase of the study animals are given decreasing amounts of venom (N=2 animals per treatment): 2.5 μg, 1.25 μg, 0.625 μg, 0.3125 ug, 0.1563 μg vs control with saline with daily swabs and biopsies as noted above.
[0089] Six adult New Zealand White rabbits were inoculated in the deep dermis with 5 μg of Loxosceles venom (SpiderPharm, Yarnell, Ariz.). Four died shortly thereafter with multiple organ failure including pulmonary edema and liver necrosis. Three more were inoculated with 4 μg of Loxosceles venom and survived. Saline-injected rabbits were used as controls. Swabs were obtained using the standard 30-second swab method with cotton and Dacron swabs daily for 21 days and biopsy material was obtained in a circular area near the infection site at one, three, seven, and fourteen days.
[0090] A similar study was performed in New Zealand White rabbits using the purified sphingomyelinase component of Loxosceles venom. Saline injection controls, cotton and Dacron swabs, and the swab technique were the same as in the whole venom experiment above. Results are as shown in FIGS. 15-19 , with venom detected as long as three weeks from the 4 and 5 ug doses.
[0091] Results show generally that cotton swabs work better than Dacron; venom can be detected out to three weeks and probably more; there is considerable animal to animal variation; the venom fraction that is essentially sphingomyelinase allows detection at least as well as whole venom, although the actual venom protein may be better represented by SpiderPharm (whole) venom; there are oscillations in venom detection day-to-day; there are significant plate-to-plate variations. Standard curves are run for each assay and the venom amounts found on different runs are not strictly comparable, although for all assays run for venom in the rabbit model for cotton, venom amounts are above background for most of the time course studied.
Example 6
Use of Venom Detection Method for Suspected Loxosceles Envenomations
[0092] FIG. 20 shows the results of assays on six specimens from suspected Loxosceles envenomations. The vertical axis shows pg/well of venom recovered, with raw absorbances corrected for control absorbances. Patients A, B, and C were all judged clinically consistent with Loxosceles envenomations, however negative ELISAs provided strong evidence against Loxosceles envenomation. Venom concentrations on all three were less than 0.32 pg, shown in the graph as 0.16 pg. Patient D was clinically assessed as a Staphylococcal envenomation and culture confirmed Methicillin Resistant Staphylococcus Aureus (MRSA), however the markedly positive ELISA established concomitant loxoscelism. Patient T from Turkey, and patient S from St. Louis were assayed via gauze and blister fluid, respectively, received via express mail. Of the six cases, a brown recluse spider was found only for patient S.
Example 7
Diagnosis of Loxoscelism in a Child Confirmed with an Enzyme-Linked Immunosorbent Assay (ELISA) and Non-Invasive Tissue Sampling
[0093] A 10-year-old South-Central-Missouri female presented with a two-day history of a painful lesion in the left axilla. The child reported that she noticed the dermal discomfort two days earlier on awakening. During this initial period, the child's mother found a dead spider (later identified) in the girl's bed. On the day prior to presentation, the child developed a headache, severe nausea, and a morbilliform exanthema.
[0094] When significant necrosis is absent, as in the case presented here, the characteristic features of envenomation are lacking, and the diagnosis is more difficult. For this case, we utilized a sensitive and ELISA designed to detect Loxosceles venom [Gomez02] using a specimen obtained by swabbing the lesion.
[0095] Examination showed a quiet and mildly apprehensive girl with pulse of 96, blood pressure of 98/60 and a temperature of 37.1 C (98.7 F). A vesicle on the left axilla was surrounded by a tender, erythematous area with streaks. ( FIG. 25 ). A fine morbilliform exanthem was present on the abdomen and back. The dead spider had been saved by the girl's mother and was later identified by an arachnologist as a member of the species Loxosceles reclusa ( FIG. 1 ).
[0096] A lesion lacking the usual necrosis or specific signs was confirmed by identification of the Loxosceles venom and further confirmed by identification of a spider found in the victim's bed, showing that the sensitive and specific ELISA of this invention, designed to detect Loxosceles venom using a specimen obtained by swabbing the lesion, can aid in diagnosis of loxoscelism.
[0097] Upon examination the day after original examination, vital signs were unchanged except for the temperature of 36.2° C. (97.2° F.). The exanthem was present as on the previous day. Serum was obtained and a surface swab specimen was obtained non-invasively from the inflamed area in the axilla, using a swab moistened with normal saline, gently rubbing the area for 30 seconds.
[0098] The specimens were flash frozen using liquid nitrogen and maintained overnight in a frost-free freezer before moving to a −20 C freezer. The specimens were transported under ice to the University of Missouri-Columbia. The swab was thawed, the absorbent end was removed from the swab stick mixed with 0.05% v/v Tween 20 and was placed in a 1.5 mL microcentrifuge tube and centrifuged at 10,000 g for 10 minutes to remove the saline from the absorbent material. The presence of venom proteins in the solution was detected with an ELISA technique for detecting Loxosceles venom originally described by Gomez et al [Gomez02], with modifications noted herein.
[0099] Polyclonal capture and detection antibodies were raised in New Zealand white rabbits with unfractionated L. reclusa venom. Antibodies were purified from serum by means of protein A column liquid chromatography [Harlow88]. The concentration of blocking agents as noted in [Gomez01] was increased and nonfat milk solids were added to the blocking buffer. The detection agent was changed from horseradish peroxidase (HRP) to alkaline phosphatase (AP) after standard curves showed greater sensitivity with the AP in the previous assay design. Product generation was monitored at 405 nm on a model ELx808, BIO-TEK, Inc. microplate reader. With the modified methodology, a 24-pg venom standard consistently produced an absorbance that was greater than background plus three standard deviations, with the standard curve as noted in FIG. 26 . Necrotic and inflammatory lesions that were tested with the ELISA had absorbances at the background level with this assay. The serum sample collected by phlebotomy also had an absorbance at the background level with this assay. The swab material from this case tested at 34.4±4.3 pg Loxosceles venom protein/well ( FIG. 26 ).
[0100] There exists a significant plate-to-plate variation in the ELISA determinations. With some assays, a 0.5 pg venom standard could be distinguished above the background levels.
[0101] Features of the case presented here, including nausea, vomiting, headache and an exanthem are seen in a minority of bites. Clinical experience suggests that significant systemic findings are more common in children and can often be associated with small lesions [Wasserman83, Anderson97]. A painful lesion, even when very small, when coupled with these systemic symptoms, can bring the possibility of loxoscelism to the fore in endemic areas when no spider is available for examination. However, for definitive diagnosis in cases where no spider is available, the test by this invention is needed.
[0102] The polyclonal swab assay presented here allowed identification of the Loxosceles venom upon the skin three days after the bite. Venom may be detected in patients for an even greater period post spider bite, e.g., up to at least about seven days. Krywko and Gomez reported detection of Loxosceles venom in dermal tissue seven days following envenomation using the rabbit model [Krywko02]. The ELISA assay coupled with a non-invasive means of specimen collection allows confirmation of small, early or atypical presentations of Loxosceles envenomation such as described in this case.
Example 8
Diagnosis of Loxoscelism in Two Turkish Patients Confirmed with an ELISA and Non-Invasive Tissue Sampling
[0103] Confirmed envenomations due to Loxosceles reclusa have not been previously documented in Turkey, to our knowledge. This example describes two Turkish patients with suspected envenomation by Loxosceles spider bites on the eyelids. Material obtained by swabbing the lesions with gauze was tested using a venom-specific ELISA. Both patients tested positive for the presence of Loxosceles venom.
[0104] Loxosceles reclusa and related arachnid species, indigenous to Europe as well as North America possess a venom capable of causing painful, disfiguring necrotic ulcers and, uncommonly, severe systemic effects [Atkins58; Wasserman83; Sams01; Anderson98]. The diagnosis of a brown recluse spider bite is a clinical one made on the basis of the morphologic appearance of the cutaneous lesion [Atkins58; Wasserman83; Sams01; Anderson98]. Definitive diagnosis is usually not possible because patients generally do not bring the offending spider to the clinician for identification. The morphology of a lesion is the usual basis for diagnosis but is not specific for Loxosceles species envenomation [Sams01; Anderson98; Vetter98], as there are many mimics of spider bites [Rosenstein87; Rees87; Moaven99]. For diagnostic confirmation of the two cases presented here, we utilized a sensitive and specific enzyme-linked immunosorbent assay (ELISA) designed to detect Loxosceles venom [Gomez02], using specimens obtained noninvasively by swabbing the lesions with cotton gauze.
[0105] Case 1: A 34-year-old Turkish woman (Case T, Example 6 above) who had gone on a sheep-dealing trip in the rural area of Siirt, Turkey awoke in her tent with swollen, painful pruritic eyelids. She reported that she had seen spiders in her tent but the species was unknown. Within three days, massive facial edema developed, and a 2×3 cm hemorrhagic eyelid lesion with superficial necrosis was present, consistent with loxoscelism ( FIG. 23 ). Upon hospital admission, she had a temperature of 38° C., with a pulse of 80 and blood pressure of 110/70 mm Hg. The results of the laboratory tests, including complete blood count, liver and renal function chemistries, urinalysis and coagulation functions, were all within normal limits. The lesion was managed with saline compresses and ocular lubrication. The lesion healed with resulting normal vision, normal eyelid function and no scarring ( FIG. 27 ).
[0106] Case 2: A 7-year-old girl from the rural area of Siirt, Turkey, awoke with pain, pruritus, and mild swelling of the eyelids. Within three days, severe bilateral eyelid edema was present. No spider was identified. On the third day, she was admitted to a hospital. A presumptive diagnosis of brown recluse spider envenomation was made based on the appearance of the lesion. A painful, tender, hemorrhagic lesion showing early necrosis surrounded by severe facial edema was seen ( FIG. 28 ). Upon hospital admission, she was normotensive with a temperature of 38° C., and a pulse of 100. She had a white blood cell count of 17,200/μL with a significant left shift. Hemoglobin and hematocrit levels, urinalysis and other blood indices were within normal limits. The eyelid lesion was managed supportively with saline compresses and ocular lubricants. The lesion healed with scarring and visible hyperpigmentation ( FIG. 29 ). Vision was normal and the eyelid could be opened fully. However, mild epiphora and punctuate epitheliopathy of the affected eyelid were observed. The child's parents observed that the right eyelid was incompletely closed when she slept.
[0107] Methods: All specimens for ELISA determination were obtained at the University of Dicle in Turkey. Gauze sponges soaked in normal saline were used to obtain a specimen from the affected lesions and contralateral control sites for both cases. The specimens were collected by gently swabbing the lesion and the control sites for 30 seconds. The swabs were taken on the 7th day after the onset of the lesion in Case 1 and on the 4th day after the onset of the lesion in case 2. Despite shipping by an express carrier, the shipments took 7 and 10 days and were stored in transit in ambient summertime temperatures for unknown durations. After shipment, the cotton samples were moistened with 300 μl of Tris buffered saline containing Tween-20 (20 mM Tris pH8.0; 145 mM NaCl; 0.02% (v/v) Tween-20) and placed in a 0.5 cm diameter plastic centrifuge tube and centrifuged at 10,000 g for 10 minutes to remove the saline from the absorbent material. Venom proteins in the solution were detected using an ELISA technique for detecting Loxosceles reclusa venom, originally described by Gomez et al. [Gomez02], with modifications noted herein.
[0108] Polyclonal capture and detection antibodies were raised in New Zealand white rabbits with unfractionated L. reclusa venom. Antibodies were purified from serum by means of protein A column liquid chromatography [Harlow88]. The concentration of blocking agents as noted in [Gomez02] was increased, nonfat milk solids were added to the blocking buffer, overnight incubation was used, and alkaline phosphatase was used as a detection agent. The generation of paranitrophenol product was monitored at 405 nm on a model ELx808, BIO-TEK, Inc. microplate reader. Separate standard curves were produced for each patient.
[0109] Results and Discussion: The contralateral control specimens all had absorbances at background level. The swab material from both cases showed venom immunoreactivity over three standard deviations greater than background signal, as shown in FIGS. 30 and 31 . These results are consistent with the presence of venom from a spider within the Loxosceles genus within the samples obtained with gauze from the lesions.
[0110] Eyelid brown recluse bites are quite uncommon [Jarvis00; Wesley85; Edwards97]. Severe edema is generally observed. Acute complications include elevated intraocular pressure [12] and airway compromise due to laryngeal swelling [Edwards97]. Long-term complications include necrosis and scarring of the eyelid, which can lead to corneal irritation [Wesley85]. Therapeutic interventions for eyelid brown recluse bites have included dapsone, systemic corticosteroids, hyperbaric oxygen [Jarvis00; Wesley85], and debridement of necrotic tissue with flap reconstruction [Edwards97]. Cantharotomy and cantholysis have been used to restore normal pressure in a case with elevated intraocular pressure [Jarvis00]. Supportive therapy can include topical and systemic antibiotics, saline dressings, and ocular lubricants. A bandage lens has been employed to minimize corneal irritation [Wesley85].
[0111] Controlled human trials supporting specific interventions for eyelid brown recluse bites are not available. One study showed benefit from a combination of dapsone and antivenom in experimental eyelid lesions in rabbits [Cole95]. However, another rabbit study reported no benefit from dapsone therapy for clinical outcome in skin lesions induced in rabbits. [Elston05]. Edwards et al. noted that “caution must be emphasized to avoid the overzealous debridement of eyelid tissue. Because of the excellent blood supply, the eyelids [have] a remarkable propensity for self-repair in the setting of gangrenous lid involvement” [Edwards97].
[0112] Although lesions attributed to Loxosceles rufescens have been reported from Turkey [Atilla04] and nearby areas around the Mediterranean [Borkan95], none of these reported spider bites were confirmed by identification of the spider known to have caused the bite. Loxosceles rufescens (Dufour, 1820) is established in Turkey [1.gantep website] and is known to cause necrotic lesions [Young01].
[0113] The massive eyelid edema and early necrosis observed in the two cases presented here are consistent with loxoscelism but not diagnostic, as other conditions, particularly envenomations from other arthropods, can have such a presentation. The venom ELISA provided supporting evidence for the diagnosis. Conservative management in the two cases reported here allowed both patients to heal without vision impairment, although one patient had residual functional impairment.
[0114] The degree of sensitivity and specificity of the ELISA for Loxosceles venom reported here has not been established in clinical cases. In vitro, the ELISA was found to be specific for Loxosceles species at relevant antigen levels, reacting to none of 17 other arthropod venoms at 40 ng [Gomez02]. In vivo, necrotic and inflammatory lesions that were tested with the ELISA had absorbances at the background level with this assay. This ELISA is not able to discriminate among Loxosceles species, which possess several common protein bands on western blot and display marked antigenic cross-reactivity. [Gomez01]
[0115] In summary, the polyclonal swab ELISA assay performed on material obtained by cotton gauze allowed identification of Loxosceles venom upon the skin 4-7 days after the onset of symptoms in the two bites reported here, supporting the diagnosis of Loxosceles envenomation by a spider of the Loxosceles genus in two Turkish patients.
[0116] A sensitive and specific Loxosceles species venom assay has been provided. In addition to the utility of rapid clinical confirmation of loxoscelism in endemic areas, a venom-based ELISA is useful in exclusion of loxoscelism in the setting of unrelated and treatable illness in nonendemic areas, in defining questionable lesions, and in guiding development of appropriate clinical treatment.
[0117] While the invention has been described in detail with respect to the specific embodiments thereof, 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. Accordingly, the scope of the present invention should be assessed as that of the appended claims and any equivalents thereto.
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Methods and immunoassays for diagnosing a bite or sting of a venomous organism in a patient having symptoms consistent with such a bite or sting are provided. A sample of venom is collected from the area of the suspected bite or sting using a swab and then contacted with an antibody that specifically binds to an antigenic site on venom present in the sample. Binding is then detected. The invention is illustrated by examples showing diagnosis of brown recluse spider bite, distinguishing it from other diagnoses with which it is often confused. This extremely sensitive test can detect venom antigens down to about 20 picograms even after the sample has been shipped and stored for periods of up to three weeks during the summer.
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This is a continuation of application Ser. No. 297,376 filed Aug. 28, 1981, now abandoned.
FIELD OF THE INVENTION
The present invention relates generally to PWM (pulse width modulated) power supplies and more particularly to a closed loop core saturation control circuit for use in a switcher-regulated PWM power supply.
DESCRIPTION OF THE PRIOR ART
Regulated power supplies employ various techniques to achieve regulation. One such technique is pulse width modulation, or PWM. PWM switching power supplies are commonly used to provide DC supply voltages in electronic devices, such as digital computers. A primary component of the power supply is the transformer. Proper operation of the transformer requires that the transformer core not become saturated. Saturation of the transformer core results from a net DC voltage being applied to the transformer windings due to a net difference in the volt-second product of each half-cycle. This difference is typically caused by asymmetry in the operation of the switching transistors due to delays in the various steps of amplification in the power supply. Unless core saturation is prevented, excessive current pulses may result, causing high EMI noise emission, loss of power supply efficiency, and lower reliability due to increased chance of transistor failure.
Several "open loop" methods are commonly used in the prior art to control core saturation. Careful matching of the switching transistors reduces the difference in transistor "on time". To block any DC component of magnetizing current from the primary winding, a capacitor is typically placed in series with the winding. On the secondary side of the transformer, the output rectifiers are usually matched to maintain equal currents and avoid accumulation of magnetic flux in one direction. In addition, the transformer core may be "gapped" to decrease permeability and inductance and increase the proportion of magnetizing current in relation to the load current. The increased proportion of magnetizing current tends to compensate for the DC offset of the circuit.
These techniques have several disadvantages. The requirement for matched components increases the cost of the system. The capacitor adds to system weight and cost, while reducing system reliability. The gapped transformer core is less efficient, requires addition of a sense winding and sensing components, and is a non-standard part.
A "closed-loop" technique involving sensing of the magnetizing current in the secondary winding and using it to adjust the symmetry of the switching transistor pulses has been attempted in the prior art. Circuits using this technique, however, are complex to design and construct, and impose special constraints on either the electronics or the transformer design which detract from their utility.
Applicant's invention provides a simple closed-loop approach to control of core saturation which is free of the above noted problems.
SUMMARY OF THE INVENTION
The present invention relates to apparatus for control of core saturation in a pulse width modulated power supply. A circuit for implementing the invention includes a track and hold amplifier for monitoring the current in the primary winding of the power supply transformer and for controlling the power supply switching transistors so as to maintain substantially equal peak currents.
It is a further feature that the amplifier includes a transistor and resistive and capacitive components.
It is yet a further feature that the amplifier includes a high frequency current spike filter.
It is an advantage of the present invention that the design will compensate for any imbalances in the primary or secondary portions of the power supply.
It is another advantage of the present invention that components in the primary or secondary portions of the power supply need not be critically matched.
It is yet another advantage of the present invention that a large decoupling capacitor in series with the primary transformer, a gapped transformer core or auxiliary sense windings are not required.
It is a further advantage of the present invention that it can be used with most standard PWM integrated circuit chips without regard to any specific electrical characteristic of the integrated circuit device, such as comparator hysteresis or error amplifier bandwidth.
It is yet a further advantage that the circuit can be analyzed using standard linear models of PWM loops.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of a prior art PWM power supply.
FIG. 2 is a schematic diagram of a PWM power supply incorporating a preferred embodiment of the invention.
FIG. 3 shows timing diagrams for the power supply of FIG. 2 under balanced current conditions.
FIG. 4 shows timing diagrams for the power supply of FIG. 2 under unbalanced current conditions.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1 a schematic diagram of a prior art PWM power supply is shown. Circuitry 100 contains the pulse width modulation logic and can be implemented with discrete components or with a commercially available PWM integrated circuit (e.g. SG3524).
Looking now at the interconnection of components, error amplifier 101 receives reference voltage VREF from a reference voltage source (not shown) and output voltage Eo. The output of error amplifier 101 is supplied to the negative input of comparator 102. The positive input of comparator 102 is connected to oscillator 103, capacitor C1, and the collector of transistor Q5. Other outputs of oscillator 103 are connected to the base of transistor Q5 and to the clocking input of flip flop 106. Capacitor C1 and the emitter of Q5 are connected to ground. The Q output of flip flop 106 is supplied to NOR gate 104 and the Q output is supplied to NOR gate 105, where they are or'ed with the output of comparator 102. The output of gate 104 is connected to the base of switching transistor Q1 while the output of gate 105 is connected to the base of switching transistor Q2. The emitters of Q1 and Q2 are connected to one end of resistor R1. The other end of R1 is connected to ground. The collectors of Q1 and Q2 are connected to opposite ends of the center-tapped primary winding of transformer 110. The center tap of the primary winding is connected to voltage source VT. The ends of the center-tapped secondary winding of transformer 110 are connected via diodes D1 and D2 to the LC filter formed by capacitor C3 and inductor L1. Capacitor C3 nd the center tap of the secondary winding are connected to ground.
Also, as discussed earlier, one or more of the techniques for controlling saturation of the core of transformer 110 would typically be used, such as core gapping, decoupling capacitors or matched output inductors.
Turning now to the operation of the circuit of FIG. 1, error amplifier 101 compares reference voltage VREF with the voltage feedback signal (Eo) and generates an error signal to the negative input of comparator 102. The positive input receives a linear ramp voltage generated by oscillator 103 and capacitor C1. The slope of the voltage ramp is determined by the size of capacitor C1. Oscillator 103, as discussed below, also provides a narrow clock pulse to flip flop 106 and a reset signal to the base of transistor Q4 at the end of each ramp period. The clock pulse triggers the two outputs of flip flop 106 to alternate states, thus giving flip flop 106 a frequency of 1/2 the oscillator frequency. The signal to Q4, which is turned off during the ramp period, permits discharging of capacitor C1.
At the beginning of each ramp, the output of comparator 102 will be low since the positive input voltage will be less than the negative input voltage. Therefore either NOR gate 104 or 105, depending on the state of Q and Q, will have both inputs low. Whichever gate has both inputs low will have a high output and, therefore, either Q1 or Q2 will be turned on, thereby allowing current to flow through the primary winding of transformer 110.
When the ramp voltage from oscillator 103 reaches the level of the error signal from error amplifier 101, the output of comparator 102 goes high causing the output of the NOR gate to go low, thereby shutting off the transistor. No current will flow in the primary of transformer 110 until the start of the next ramp period. The ramp voltage continues to rise until the voltage at the positive input of comparator 102 reaches the oscillator 103 reset level. At that time, oscillator 103 turns on Q5 to discharge C1, thereby dropping the ramp voltage to substantially zero, and sends another clocking pulse to flip flop 106 to change the state of Q and Q. Whichever NOR gate had been disabled during the prior ramp period because of the presence of a high signal from flip flop 106 will now be enabled and current can flow through the other transistor until the output of comparator 102 again goes high. Current will therefore alternately flow through either Q1 or Q2 at the beginning of each ramp period. The fractional part of the ramp time which Q1 or Q2 is on is controlled by the output of error amplifier 101 to maintain Eo at the desired level.
In this embodiment, current limiting is provided by Q3. If the current through Q1 or Q2 exceeds a maximum level, Q3 will turn on, thereby pulling the negative input of comparator 102 to ground and causing the output of comparator 102 to go high. This will, as explained earlier, cause the transistor to turn off and stop the current flow.
Referring to FIG. 2, a PWM power supply incorporating core saturation control logic 120 is shown. Saturation control logic 120 is connected to the emitters of Q1 and Q2 and to C1 and acts as a low impedance track and hold unity gain amplifier which monitors the current signal as sensed by R1 and applies an output in series with the ramp signal from oscillator 103. This provides a current feedback path within the PWM loop.
The current signal from the emitters of Q1 and Q2 is connected to one end of resistor R2, the other end which is connected to the base of transistor Q5. The collector of Q5 is connected to a voltage source, VREF in this embodiment, and the emitter is connected to capacitors C1 and C2, and resistor R3. C2 and R3 are, in turn, connected to ground. Capacitor C4 may be connected between the base of Q5 and ground, if required, as an input filter to eliminate noise between grounds and to filter any high frequency turn-on current spike. To eliminate comparator 102 output "jitter", the value of the time constant of R3 and C2 is chosen such that the total signal to comparator 102 always has a positive slope until the ramp signal is reset.
The current feedback signal will be synchronous with the frequency of oscillator 103 and will add with the linear ramp waveform. This changes the voltage seen at the positive input of comparator 102, thereby modifying the output. This appears as a slight gain reduction of the forward loop. Due to the high DC gain of error amplifier 101, the loop gain change is compensated for in steady state operation by a corresponding shift in the error voltage to the negative input of comparator 102, thereby maintaining regulation of output voltage Eo.
If the currents flowing through Q1 and Q2 are unbalanced, saturation control logic 120 will sense and adjust the ramp signal to comparator 102 such that the on-times of Q1 and Q2 are controlled in a manner which would compensate for and reduce the magnitude of current asymmetry. Logic 120 will, therefore, continuously correct for imbalances or component mismatching in either the primary or secondary circuits of the power supply. No additional reset logic is required, since Q5 will discharge C2 during its normal discharging of C1.
Looking at FIG. 3 timing diagrams are shown for balanced currents in the power supply of FIG. 2. At t1, a reset has just been performed and the ramp voltage is approximately zero. Since the ramp voltage is less than the output voltage of error amplifier 101, the output of comparator 102 will be low. Since flip flop 106 output Q is also low at this time, Q1 will be turned on and current begins to flow. At time t2, the ramp voltage equals the output voltage of error amplifier 101. This causes the output of comparator 102 to go high, which turns off Q1.
At time t3, the ramp voltage reaches the reset level of oscillator 103. Oscillator 103 then resets the ramp voltage and voltage Vo via a signal to Q4 and alternates the state of the outputs of flip flop 106. This time Q is low, therefore, Q2 will be turned on and will carry the current rather than Q1. At time t4, the output of comparator 102 goes high, turning off Q2 and stopping current flow. At time t5, oscillator 103 again performs its reset and flip flop functions and the cycle repeats. Since the currents are balanced, Q1 on-time TQ1 and Q2 on-time TQ2 are substantially equal.
Looking now at FIG. 4, timing diagrams similar to FIG. 3 are presented. In FIG. 4, however, the currents are unbalanced, as would be the case if the core had become momentarily saturated by a shift in volt-second product. It can be seen that the slope of the current signal is different between Q1 and Q2 and that the peak currents would be asymmetrical if TQ1 and TQ2 are equal. This higher current rate of Q1 is, however, sensed by Logic 120, which increases the slope of the ramp voltage to comparator 102. This causes the ramp voltage to equal the output of error amplifier 101 in a shorter period of time, thereby tending to equalize the volt-second products of Q1 and Q2. That is, Logic 120 manipulates the on-times of Q1 and Q2 by means of modification of the ramp voltage such that Q1 and Q2 have different on-times (i.e. TQ1 does not equal TQ2) to yield substantially equal peak transformer currents, thereby controlling core saturation.
The invention may be embodied in yet other specific forms without departing from the spirit or essential characteristics thereof. For example, the current can be sensed by means other than the sensing resistor, such as with a current sensing transformer or a Hall-effect current sensor. Also, the function of Logic 120 could be performed by a linear amplifier, in either a single-ended or differential configuration, or capacitor C2 may be eliminated if the comparator has sufficient hysteresis such that jitter is avoided at transistor turn-off.
The present embodiments are therefore to be considered in all respect as illustrative and not restrictive. The scope of the invention is indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
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A closed-loop core saturation control circuit for use in pulse width modulated power supplies is disclosed. The circuit uses a single transistor as a unity gain, low impedance track and hold amplifier to sense the current in the primary winding of the transformer and supply a related voltage to the power supply comparator, where it sums with the linear ramp voltage. The on-times of the switching transistors are therefore individually controlled and varied such that both switching transistors will see substantially equal peak currents.
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